STEAM SYSTEMS REQUIRED FOR DIFFERENT PROCESSES SUCH AS SOAKING, PRE AND POST STEAMING AS WELL AS DRYING
| Problem | Solution | Benefits |
| Getting Steam at the rated Capacity and Pressure | Steam Boilers / Thermic Fluid Heaters | Boilers and Heaters of optimum capacity can help in efficient steam production Correctly designed boilers can help save production and fuel costs greatly |
| Problem | Solution | Benefits |
| Operating Pressure Is Less Than the Required Plant Pressure | Operate The Boiler Nearer to Design Pressure | Reduction in process steam demand. |
| Non-Uniform Blowdown | Auto Blowdown System | Adequate blowdown eliminates scale carry over and results in heat loss optimization Avoids excess chemical dosing and ensures optimum level of TDS of the water inside boiler |
| Lower Feed Water Temperature | Feed Water Management System | Directly reduces fuel consumption. |
| Water Carry Over | Moisture Separator | Ensures removal of moisture carry over to the process, resulting in dry steam to the process, which helps in improving productivity, quality and fuel savings |
| Problem | Solution | Benefits |
| Higher Pressure Than Rated, Open Steam is Used Without Pressure Reduction but By Throttling the Valve | Pressure Reducing Station | At lower pressure latent heat is higher so there is steam saving through PRS |
| Smaller Steam Line Size | Steam line Sizing as per Required Steam Flow | Smaller line size always creates pressure drop issues as per Barnauli’s principle and to get the same flow velocity of steam increases resulting moisture carryover |
| No Provision of Automatic Air Venting | Automatic Air vent For Steam Inlet Line to Equipment and Header | Automatic air vents eliminate barrier of heat transfer between steam to condensate |
| Problem | Solution | Benefits |
| Higher Pressure Than Rated, Open Steam Is Used Without Pressure Reduction but By Throttling the Valve | Pressure Reducing Station | At lower pressure latent heat is higher so there is steam saving through PRS |
| Smaller Steam Line Size | Steam line Sizing as per Required Steam Flow | Smaller line size always creates pressure drop issues as per Barnauli’s principle and to get the same flow velocity of steam increases resulting moisture carryover |
| No Provision of Automatic Air venting | Automatic Air vent For Steam Inlet Line to Equipment and Header | Automatic air vents eliminate barrier of heat transfer between steam to condensate |
| Problem | Solution | Benefits |
| Achieving Desired Temperature | PID Based Hot Water Generator | Stable water temperature leads to no variation in soaking time Increased steam savings |
| Problem | Solution | Benefits |
| Desired Temperature for Rice Drying not Achieved | PID Based Temperature Control System | Improved grain quality because of controlled air temperature |
| Higher Pressure Than Required | Pressure Control System | Increased steam savings |
| No Provision of Automatic Air Venting | Automatic Air Vent for Steam Inlet Line to Equipment and Header | Automatic air vents eliminate barrier of heat transfer between steam to condensate |
| Increased Batch Timing due to Group Trapping | Steam Operated Pumping Trap | Condensate evacuation results in uniform heat transfer Reduced batch timings and steam consumption |
| Problem | Solution | Benefits |
| Many Plants are Not Recovering Flash Steam and Condensate | Condensate should be Recovered by Online Steam Operated Condensate Recovery System | It helps in reduction of makeup water consumption, no need to recover evaporator water where chances of contamination are much higher All indirect injection will lead to condensate recovery factor of 75% |
| Problem | Solution | Benefits |
| Many Plants Have a Problem with Valves Leaking Steam | Seatless and Glandless Valves | Piston Valves are class VI valves and by using them, we can create a plant having zero steam leak Ensures minimal pressure drops, safe working environment |
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