What Is a Condensate Return System? A condensate recovery system consists of drain lines and steam traps. They are designed to collect the condensate and move it along quickly and efficiently, so heat is not lost during the process, and reheating doesn’t need to occur to heat it back to steam.
Why to return condensate to the boiler?
- Summary of reasons for condensate recovery:
- Water charges are reduced.
- Effluent charges and possible cooling costs are reduced.
- Fuel costs are reduced.
- More steam can be produced from the boiler.
- Boiler blowdown is reduced - less energy is lost from the boiler.
- Chemical treatment of raw make-up water is reduced.
How does condensate return to a boiler?
- Backpressure from lift created by an elevated collection tank
- Piping friction caused by transporting condensate over distance
- Pressurized Collection Tank or Flash Vessel
- Condensate directly returned to the boiler
How to Defrost Your condensate pipe?
- Use gravity – pipes should fall as directly and steeply as possible. ...
- Have a siphon trap – if you're getting a new boiler, consider one with a 'siphon trap' type of condensate water release. ...
- Install a 'trace' system – if you live in an area where temperatures drop below freezing for several days at a time, ask your installer about trace systems. ...
How to drain condensate from furnace?
You can resist subsequent obstructions by doing the following chores regularly:
- Clean the area around your indoor unit with a vacuum to remove any dirt or debris that may have made its way into the drain.
- Keep the area all around the drain’s end clean and clear of debris. ...
- If the condensate drain becomes plugged, turn off the electricity to your air conditioner at the main circuit breaker. ...
What is the purpose of a condensate system?
The steam/condensate systems are an integral part of the water boiler system. The condensate system includes anywhere that the steam condenses to form liquid water. As the vapor leaves the low-pressure turbine it contains droplets of water.
Why is it important to re use condensate return?
Returning more condensate to the feedtank reduces the need for blowdown and thus reduces the energy lost from the boiler.
How does condensate return back to the boiler?
Condensate under pressure and above 212F can be flashed to steam for additional energy value/recovery. Condensate is collected at each point of steam use and in long steam pipe runs. It is then pumped back to the boiler using steam pressure or electric-operated pumps.
What is a condensate return tank?
August 17, 2021. Condensate tanks are part of a condensate return system, and are used to store all the condensate water returned from a steam system. They are typically located near the boiler and their size is determined by the steam load on a system.
What is difference between steam and condensate?
Condensate is the liquid formed when steam passes from the vapor to the liquid state. In a heating process, condensate is the result of steam transferring a portion of its heat energy, known as latent heat, to the product, line, or equipment being heated.
How does condensate return improve the economics of boiler operation?
If condensate is returned, the need for make-up water is reduced. Dropping the make-up water quantity yields a lower consumption of boiler chemicals. Water costs are rising everywhere and a high condensate return ratio reduces the total make-up water costs.
Where does condensate come from?
Condensate is mainly composed of propane, butane, pentane and heavier hydrocarbon fractions. The condensate is not only generated into the reservoir, it is also formed when liquid drops out, or condenses, from a gas stream in pipelines or surface facilities.
How does a condensate return pump work?
The goal is to pump hot condensate from low points in the building back to the boiler system as quickly as possible. The condensate flows by gravity from the steam traps down into the condensate receiver and the water/condensate level in the receiver rises. There is a float or mechanical alternator in the receiver.
What is boiler condensate return piping?
Piping for Two-Phase Flow The piping used to transport condensate is typically called “condensate recovery piping” or “condensate return piping”. The design sizing of such piping requires significant specialization because condensate recovery piping collecting from steam traps must be designed for two-phase flow.
What means condensate?
Definition of condensate : a product of condensation especially : a liquid obtained by condensation of a gas or vapor steam condensate.
How does a condensate tank work?
The Purpose of Condensate Tanks As the boiler heats water, a substantial amount of condensation occurs. Instead of letting this valuable moisture simply evaporate, a condensate receiver, also called a condensate tank, captures it and sends it back to the boiler room so it can be reused.
Why is condensate considered a valuable resource?
why is condensate considered a valuable resource? corrosion coupons are made of the same material as heat exchangers. Damage done to them is usually similar to the inside of pipes.
How can I reuse condensate?
Condensate reuse may include subsurface irrigation or process makeup (such as a cooling tower), where water is treated for biological contamination. If it is to be used for potable water or for washing, proper disinfection of the water is required.
Can you drink condensate water?
Moreover, the condensate can contain lead and other metal residues from the component parts of the dehumidifier. Unlike distilled water (see Nitty Gritty), dehumidifier water is never sterilized through boiling. In case you were still entertaining the thought, let me make it clear: do not drink the condensate!
Is condensation water from AC good for plants?
The water produced form the air conditioner is purely condensate water like that from a cold glass of ice tea on a hot summer day and is totally safe to use and harvest in a bucket outside of your home to water your plants.
Can you reuse air conditioner water?
The water can be used to irrigate an outdoor garden or for indoor plants. The water will be clean and clear as it will not contain chlorine or other additives that can harm your plant life. You can place the water in a can for watering, or redirect the water to be used for watering a garden directly.
What temperature can condensate be flashed to steam?
Condensate under pressure and above 212F can be flashed to steam for additional energy value/recovery. Condensate is collected at each point of steam use and in long steam pipe runs. It is then pumped back to the boiler using steam pressure or electric-operated pumps.
Why is it important to have a small drip leg?
Due to the velocity at which steam and condensate flows in a steam line, it is important to have the drip leg adequate in size. This is to allow the condensate to flow “into” instead of “over” a drip leg, as its purpose is to remove all condensate in the line. Remember condensate will reduce the quality of the steam in a system. Too small a drip leg is similar to having a golf ball pass “over” the center of the cup due to the speed at which it is traveling.
What is condensate in boiler?
Introduction. Condensate (water or condensed steam) reduces the quality of the steam but is too high value to discard. Condensate can contain up to 20% of the energy required to make the steam in the boiler. Maximize the amount of condensate that is returned to the boiler to save both energy and water treatment chemicals.
Why is condensate important in boilers?
Maximize the amount of condensate that is returned to the boiler to save both energy and water treatment chemicals. The value of the condensate varies with its pressure and temperature which depends on the operating pressure of the steam system.
How small should a drip leg be?
Steam main drip legs should be sized at the same diameter of the pipe, up to 4″, on mains above 4″ it should be one half the diameter but never less than 4″.
Can concentric couplings settle in a line?
Never use “Concentric” couplings as this will allow condensate to settle in the line. Ensure that the condensate piping is adequately sized. Condensate piping has to accommodate two-phase flow B liquid and vapor. The vapor portion of the condensate stream is more voluminous than the liquid portion.
What is flash steam?
The flash steam generated from condensate can contain up to half of the total energy of the condensate. An efficient steam system will recover and use flash steam. Condensate and flash steam discharged to waste means more make-up water, more fuel, and increased running costs.
What is steam condensate?
As well as having heat content, the condensate is basically distilled water, which is ideal for use as boiler feedwater. An efficient steam system will collect this condensate and either return it to a deaerator, a boiler feedtank, or use it in another process.
Why is steam used in power plants?
Steam is usually generated for one of two reasons: To produce electrical power, for example in power stations or co-generation plants. To supply heat for heating and process systems. When a kilogram of steam condenses completely, a kilogram of condensate is formed at the same pressure and temperature (Figure 14.1.1).
How much heat does a hot condensate have?
Hot condensate at 7 bar g has a heat content of about 721 kJ/kg. When it is released to atmospheric pressure (0 bar g), each kilogram of water can only retain about 419 kJ of heat. The excess energy in each kilogram of the condensate is therefore 721 – 419 = 302 kJ.
Does colder boiler water reduce steaming rate?
Colder boiler feedwater will reduce the steaming rate of the boiler. The lower the feedwater temperature, the more heat, and thus fuel needed to heat the water, thereby leaving less heat to raise steam. Boiler feedwater quality. Condensate is distilled water, which contains almost no total dissolved solids (TDS).
How long does a condensate tank last?
The receiver or tank on a condensate unit is designed to be as small as possible. Most units utilize the traditional constant speed on-off pump operation. The receiver is sized for about 45-60 seconds of storage. The pumps are sized for two times the condensing rate. This will allow the pump to operate for at least 20-30 seconds on and 30-60 seconds off under the highest capacity of the served terminal units.
How does a condensate pump work?
The condensate flows by gravity from the steam traps down into the condensate receiver and the water/condensate level in the receiver rises. There is a float or mechanical alternator in the receiver. When the level rises high enough to make the contacts on the float, the pump starts and sends the condensate out of the receiver and back to ...
How many pumps are needed for a condensate pump?
Most condensate units have two pumps so there is a standby pump. When using two pumps, there is normally an alternator for the pumps. In addition to alternation, there can be two floats or a two-level mechanical float alternator with a higher level sensor so if the pump cannot keep up, the second pump comes on.
Can a receiver fit two pumps?
Simple, the receiver is not big enough to fit two pumps on it! Although this is bigger than needed, the balance valve installed on the discharge of the pump will throttle the pump so the pump will pump 20-30 seconds. The off cycle will be a bit longer. This system is inexpensive, in stock, and simple.
Do condensate pumps have receivers?
Condensate units normally have small receivers, and the pump starts based on the level control IN THE RECEIVER. This will differ greatly from boiler feed units which I will examine next week in the R. L. Deppmann Monday Morning Minutes.
How does condensate return affect boiler efficiency?
Returning condensate also increases efficiency of the boiler by reducing the required temperature increase of the feed water.
Why is return condensate important?
Returning condensate also increases efficiency of the boiler by reducing the required temperature increase of the feed water. In both boiler feed and condensate return applications, flow measurement is of the utmost importance to ensure water quality and proper efficiency throughout the application. Overview.
Why is it important to dispose of compressed air properly?
It is very important to dispose of condensate properly as not to violate any environmental laws. When released into the air by the compressed air equipment, the condensate consists of tiny particles of oil that are not visible to the naked eye. This is why it needs to be disposed of correctly, so it does not negatively impact the environment. Condensate should never be discharged on a walkway or near foot traffic due to slipping hazards. There may also be fines or a damaged reputation at stake when improper disposal is revealed, which can be devastating to a company.
Is a condensate recovery system worth it?
These details must be taken seriously to prevent future problems, but with proper education and guidance, a condensate recovery system is reliable and well worth it.
Is condensate return good for dry cleaning?
Utilizing a condensate return system has numerous benefits for dry-cleaning businesses. However, many business owners are in the dark about this concept. If you aren’t sure exactly what a condensate return system does, or even if you know the basics, learning about what condensate is and why you should take advantage of it can be crucial to your time and bottom line.
How Does A Condensate Tank Work?
A condensate tank is the collection tank in which all returning condensate is collected. There are three reasons we want to collect and use condensate returns:
We Can Help
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