MAXIFLO EJECTOR SYSTEM AN INNOVATIVE APPROACH TO STEAM CONSERVATION LEVEL 4 BEE ACCREDITED

Transcription

1 MAXIFLO EJECTOR SYSTEM AN INNOVATIVE APPROACH TO STEAM CONSERVATION LEVEL 4 BEE ACCREDITED

2 INTRODUCTION The Maxiflo is a highly efficient condensate removal system which is an alternative to conventional steam traps. Unlike steam traps, the Maxiflo has as no moving parts and harnesses kinetic energy from steam, to eject condensate continuously. The rapid ejection process improves thermal efficiency of process equipment by up to 20%.

3 CONDENSATE REMOVAL SYSTEMS PART 1 Condensate removal with steam traps. PART 2 Condensate removal with the Maxiflo ejector system.

4 CONDENSATE REMOVAL WITH STEAM TRAPS Steam traps are automatic valves which cycle open to discharge condensate from equipment and close to retain the live steam.

5 COMMON TYPES OF STEAM TRAPS Inverted Bucket Trap Float & Thermostatic Trap Thermodynamic Trap Thermostatic Trap

6 INVERTED BUCKET

7 FLOAT & THERMOSTATIC

8 THERMODYNAMIC TRAP

9 THERMOSTATIC TRAP

10 DISADVANTAGES OF STEAM TRAPS They require regular testing & maintenance to operate efficiently. Different types of traps require different test equipment and procedures.

11 TYPICAL MAINTENANCE PROGRAM According to the manufacturers, steam traps should be tested 2 to 3 times a year. Faulty traps must be repaired or replaced, immediately after detection.

12 THERMAL IMAGES OF STEAM TRAPS ON SIMILAR APPLICATIONS Failed open Working order

13 ACTUAL FAILED TRAPS Trap internals eroded from steam blow. Ball floats damaged from waterhammer.

14 THE RESULT OF TRAP FAILURE Because the default failure mode of steam traps is in the open position, just one failed open trap at 10 bar can cost R per year in steam loss.

15 CONDENSATE REMOVAL WITH THE MAXIFLO EJECTOR SYSTEM The Maxiflo ejector is an alternative system which uses kinetic energy from steam, to discharge condensate from equipment, while retaining the live steam.

16 MAXIFLO RANGE 15, 20, 25, 40 & 50 mm Nominal Bore Screwed, Flanged, Socket weld or Wafer

17 MAXIFLO SYSTEM Has no moving parts. Stainless steel construction.

18 THE DIFFERENCE BETWEEN MAXIFLO AND STEAM TRAPS Steam traps have moving parts and discharge condensate in cycles. Maxiflo ejectors are static and use kinetic energy from steam to eject condensate continuously. Principle of operation to follow

19 THE DENSITY OF STEAM COMPARED TO CONDENSATE

20 As steam and condensate travel towards the Maxiflo ejector : - Both try to pass through the ejector at the same time. The higher density condensate is always forced through first, by the steam pressure. The turbulent condensate discharge through the ejector effectively blocks the steam passage.

21 THEORY CONFIRMED BY THERMAL IMAGE OF MAXIFLO The continuous discharge of condensate (maroon) holds the steam (yellow) back in the line.

22 EXAMPLE OF MAXIFLO ON A CORRUGATING ROLL

23 MAXIFLO DISCHARGE CHARACTERISTICS The Maxiflo can discharge a large mass of condensate, but only a small mass of steam. The reason being that condensate has a greater density than steam. animation to follow

24 In 1 hour, all the condensate discharged through the ejector, but only 6.5 % of the steam was able to discharge.

25 SIZING OF MAXIFLO EJECTOR FOR CORRUGATING ROLL Size at operating pressure of equipment. Size to remove maximum condensate (start-up load). Determine acceptable steam loss under normal operating loads.

26 DECLARED STEAM LOSS FROM TRAPS IN WORKING ORDER (BY MANUFACTURERS)

27 MAXIFLO PERFORMANCE CURVE OF CORRUGATING ROLL Operating press = 15 bar Max - operating load = 214 kg/hr (start-up) Min - operating load = 54 kg/hr Max steam loss = 1.4 kg/hr

28 MAXIFLO IN OPERATION ON CORRUGATING ROLL Kinetic energy from the exhaust steam accelerates the condensate discharge.

29 THERMAL IMAGE OF MAXIFLO IN OPERATION ON CORRUGATOR ROLL Kinetic energy draws condensate (maroon) out continuously and completely from the roll, while steam is retained for maximum heat transfer.

30 HOW MAXIFLO SAVES STEAM PRIMARY SAVINGS: Maxiflo uses kinetic energy from steam to draw condensate from heat transfer surfaces, faster than any mechanical steam trap. Air and non-condensable gases are also vented continuously during operation. SECONDARY SAVINGS: Permanent elimination of excessive steam loss from worn and failed traps.

31 PRIMARY SAVINGS: MAXIFLO REDUCES AIR AND CONDENSATE BARRIERS

32 THE EFFECTS OF AIR AND CONDENSATE BARRIERS TO HEAT TRANSFER Reducing air and condensate barriers improves thermal efficiency by up to 20%

33 SECONDARY SAVINGS: MAXIFLO DOESN'T WEAR AND FAIL OPEN TYPICAL STEAM LOSS TABLE AT 10 BAR LIFE SPAN TYPICAL STEAM TRAP LOSS MAX. PERMISSIBLE MAXIFLO LOSS 1 st year 2.5 kg/hr 2.5 kg/hr 2 nd year 3.5 kg/hr 2.5 kg/hr 3 rd year 7 kg/hr 2.5 kg/hr 20 years 7-50 kg/hr 2.5 kg/hr As moving parts wear, steam loss from traps increase progressively, until total failure.

34 ADVANTAGES OF MAXIFLO Proven life span over 20 years. Results in sustainable steam savings. Improves efficiency of equipment. Requires only low maintenance.

35 BENEFITS OF TOTAL PLANT CONVERSION Steam savings of 15% - 30% achieved. Improved performance of process equipment. Reduced steam trap maintenance. Before Maxiflo After Maxiflo