Steam Systems

Optimization (SSO)
Introduction to SSO
Awareness Session UNIDO
Purpose of this presentation…

To introduce the concept of energy

efficiency applicable to industrial
heating systems
and
the steam system optimisation (SSO)
training programme for Palestine
In this presentation…
Overview of UNIDO

Steam optimisation: the systems approach

Overview of course content

Steam system opportunities

Steam system tools available

The UNIDO steam systems training

programme
Industrial Energy Efficiency
Objectives of the UNIDO IEE Programme
Work together with counterparts, stakeholders and partners to:

Ø Strengthen policy and regulatory

frameworks for better & sustainable EE
performance in industry
Ø Accelerate adoption and wide
dissemination of IEE best-available
practices and technologies
Ø Save energy and reduce GHG emission
of the industrial sector
Ø Integrate EE in industry daily business
Productivity Job
practices for sustainable increased
Creation
productivity and competitiveness
Competitiveness
UNIDO Industrial Energy Efficiency Portfolio
30 Countries

& Palestine
Impact of UNIDO-GEF EnMS-ISO 50001-ESO Program
ESO”

7,500 GWh of
final energy = Annual energy
OR
5 years energy
OR
CO2 emissions of
savings production of 1,875,000 middle
consumption of
1,230,000 400 1 MW wind class cars (running
EU households turbines 12,500 km per year)

§ Organization-wide energy savings in first 1-2 years range from 4% to 15%,

with little or no capital investments
§ Cumulative cost savings of beneficiary companies estimated to exceed USD
250 mio without considering non-energy benefits
§ Direct GHG emission reductions of more than 4.8 million tCO2
§ Sustainable pipeline of IEE investments generated
 Climate Change Policy Scenarios

60
Renewables 30%
50
Emission Gt CO2

CCS/ CCUS 13%

40
Power generation efficiency &
30 fuel switching 1%
End-use fuel switching 10%
20
End-use fuel & electricity
10 efficiency 38%
Nuclear 8 %
0

Source: International Energy Agency

2012 2020 2030 2040 2050
Relation between EnMS and ESO’s
Motor Systems (MSO)

Motor Driven Compressed Air Systems (CSAO)

Systems Pump Systems (PSO)
Fan Systems (FSO)

Steam Systems (SSO)

Energy Industrial Heating Solar Thermal for Industrial Heat (SHIP)
Management
Process Heat Optimization (PHO)
Systems
(EnMS) Refrigeration Systems (RSO)
Industrial Cooling (1)
Chillers & HVAC

Energy Performance Indicators (EnPI)

(1) There are also motors Energy Metrics GHG Emissions Accounting
in cooling systems Baselines & Benchmarking
UNIDO Output - Capacity Building Modality (ESO’s)
Elements, Participants International Experts
and Modalities
Awareness
Seminars
(2 hrs)

USER
Training
(16 hrs)

EXPERT
Training Candidate Plant
(>15 days) Host Plant
 Steam:
The Systems Approach
Industrial Heating Worldwide
Industrial processes account for half of global heat consumption, whilst the
other half is mainly used in buildings for space and water heating as well as
for cooking and agriculture1
Why use steam in industry?

• Extremely efficient as a heating source – constant temperature,

highest heat transfer (condensing) coefficients
• Extremely cost effective to distribute to point-of-use
• Can be controlled very accurately
• A very flexible energy transfer medium – can be used for process
heating as well as power generation
• Technology and applications are tried and proven at large as well as
small-scale
• Significant system benefits!
Small Steam Users Medium Steam Users
• Laundries • Large commercial
• Bakeries heating
• Cooking • Paint booths
• Metal Fabrication • Humidification systems
• Electronics • Large chiller systems
Industrial Steam System Optimisation

• Needs to follow a SYSTEMS Approach

• Focuses on how steam system energy is managed in a plant
• Industrial steam demands change over time and operations
of steam system assets should be optimized on a continuous
basis
• Best practices during design, procurement, operations and
maintenance must be followed
• Understanding of the fundamentals and tools and resources
available is key for a SSO program
Generic Steam System Components

Distribution

End Use

Recovery

Generation

1 17
Optimising steam systems: Questions to ask

1. What are the current system conditions and operating parameters?

2. What are the thermal energy requirements for both the supply and
demand sides of the heat process system?
3. Where is energy being lost or wasted?
4. Is there a way to reuse, recycle, or recover excess heat from
process flows, air streams, or condensate flows?
5. Is the fuel the most appropriate available for the heat application at
hand?
6. Is there an opportunity to generate and integrate renewable energy
into the heat process?
7. Are there opportunities for cogeneration?
Overview of Course Content
Course Outline – User Training

User training

1. Overview and fundamentals 5. Optimising steam distribution

of steam 6. Optimising steam end use
2. SSST - Steam system scoping 7. Optimising condensate
tool recovery
3. SSMT – Steam system 8. Opportunities for
modelling tool cogeneration
4. Optimising steam generation 9. Steam tools and resources
Steam System Components

• Boiler • Steam turbines

Generation • Boiler auxiliaries End-use • Heat exchangers
• Water treatment equipment • Live steam injection
• De aerator • Stripping columns
• Feed water Pumps • Evaporators, etc
• Fuel storage and handling
equipment

• Steam piping • Steam traps

Distribution • Pressure reducing Recovery • Condensate recovery
stations and return system
• Condensate pumps
Equipment

Induced draft fan

Feedwater pump
De-aerator
Fire tube boiler
Equipment

Piping

Flash tank

Steam trap Drier

Heat exchanger
Fundamentals
In order to properly evaluate steam
systems the physics of each process
must be understood

Thermodynamics

Heat transfer
Fluid flow

Process measurements
• Temperatures, Pressures,
Flows, etc.
Phase change for water

24
Temperature Enthalpy Saturation Curve
Conservation of Energy Calculation
Optimisation techniques

Optimising
Generation • Improve Boiler Efficiency
• Blow down Management
• Feed water Economisers and
Combustion Air Preheaters
• Excess Air Control
• Fuel Switching

Optimising
Distribution • Steam Leaks
• Heat Transfer Loss Through
Insulation
Optimisation techniques
Optimising • Types of Steam Traps
Condensate
• Steam Trap Management
Recovery Program
• Evaluation of Condensate
Recovery Systems
• Condensate Flash Tanks
• Condensate Return Temperature
Common Best Practices - Generation

§ Minimize excess air

§ Install heat recovery equipment
§ Clean boiler heat transfer surfaces
§ Improve water treatment to reduce boiler blowdown
§ Recover energy from boiler blowdown
§ Add/restore boiler refractory
§ Minimize the number of operating boilers
§ Investigate fuel switching
§ Optimize deaerator vent rate
Source: US DOE BestPractices Steam System Sourcebook

4 84
Common Best Practices - Distribution

§ Repair steam leaks

§ Minimize vented steam
§ Ensure that steam system piping, valves, fittings
and vessels are well insulated
§ Isolate steam from unused lines
§ Minimize flows through pressure reducing
stations
§ Reduce pressure drop in headers
§ Drain condensate from steam headers Source: US DOE BestPractices Steam System Sourcebook

5 34
Common Best Practices – End-Use

§ Reduce steam usage by a process

ü Improving the efficiency of the process
ü Shifting steam demand to a waste heat source
§ Reduce the steam pressure needed by process,
especially in cogeneration systems
§ Upgrade low pressure (or waste) steam to
supply process demands
§ Process integration leading to overall energy
optimization of the plant Source: US DOE BestPractices Steam System Sourcebook
Common Best Practices – Recovery

§ Implement an effective steam-trap management and

maintenance program
§ Recover as much as possible of available condensate
§ Recover condensate at the highest possible thermal
energy
§ Flash high-pressure condensate to make low- pressure
steam
Source: US DOE BestPractices Steam System Sourcebook
Steam System Tools
Tools

In order to properly evaluate steam US DOE Tools Suite

systems the physics of each process must
be understood

Steam System Survey Guide

Thermodynamics
Steam System Scoping Tool (SSST)
Heat transfer
Steam System Assessment Tool (SSMT)
Fluid flow Insulation evaluation software – 3E-Plus

• Several other commercially available software tools for steam systems

• Process measurements
Steam System Sourcebook

Includes Three Main

Sections::
Steam System Basics

Performance Improvement
Opportunities

Programs, Contacts, and

Resources
US DOE Steam System Scoping Tool - SSST

§ SSST is a software-based questionnaire designed to enhance

awareness of areas of steam system management
§ Divided into typical steam system focus areas
§ Provides the user a score that is indicative of management
intensity and serves as a guide to useful information
§ Tool to identify potential improvement opportunity areas
§ Will NOT quantify the energy savings opportunities

2 5
SSST Scorecard – Results

§ What is the condition of your system?

POSSIBLE TYPICAL
SUMMARY OF RESULTS SCOPING TOOL AREAS SCORE SCORE

1 STEAM SYSTEM PROFILING 90 63%

2 STEAM SYSTEM OPERATING PRACTICES 140 69%
3 BOILER PLANT OPERATING PRACTICES 80 63%
4 DISTRIBUTION, END USE, RECOVERY OP. PRACTICES 30 58%
TOTAL SCOPING TOOL QUESTIONAIRE SCORE 340 222
TOTAL SCOPING TOOL QUESTIONAIRE SCORE 100% 65%

§ Allows for identifying potential improvement opportunities and focus

areas
Source: US DOE ITP Steam Best Practices Program
Steam System Assessment Tool (SSMT)

q Developed for the U.S.DOE Office of

Energy Efficiency and Renewable Energy
§ Michael B. Muller
§ Oakridge National Laboratory

q Steam System Modeler Tool (SSMT)

§ Steam system modelling software
§ Common energy recovery projects
built into the model
§ Allows “what if” evaluations

q Freely available
SSMT – Sample Input for Boiler
Custom Steam Property Tables
• Saturated Steam Property
Calculator
• Sub-cooled liquid to
Superheated Gas
Equipment Calculators
• Boiler
• Heat loss
• Flash Tank
• PRV with Superheating
• Header
• Deaerator
• Steam Turbine
Steam System Modeler
Preferences: (Customizable Units,
Language, Currency)
SSMT – Sample Model
SSMT – Sample Output (improvement project)

Base case

Improvement
Case Study – FMCG company in South Africa

§ AMKA Products manufactures more than 400

products that include shampoos, lotions, skin creams,
hair relaxers, bubble baths, cleaning chemicals and
dishwashing liquids.
§ Products are distributed throughout South Africa, as
well as to 34 other countries in Africa.
§ The company employs more than a 1000 people.
§ Currently four manufacturing facilities exist with a new
facility commissioned.
Case Study – FMCG company in South Africa

§ The site was assessed using the Steam System Scoping Tool, and
measurements were taken.
§ These included ultrasonic and thermal analysis of steam traps, surface
temperature measurements, boiler flue gas analysis and boiler forced draft
fan power measurements.
§ Mass and energy balances were used to allow modelling of steam
consumption and condensate recovery rates.
§ Individual elements of the steam system were evaluated followed by a
systems-level analysis using the Steam System Modelling Tool.
§ Opportunities were identified and potential savings were quantified, with the
most attractive options prioritised for implementation.
Case Study – FMCG company in South Africa

Savings Energy GHG Emission

Investment Payback
Steam Intervention ZAR/ saving reduction (kg
ZAR Yrs
annum (kWh) Co2 / year)

Boiler forced Installation of variable speed drive &

30,000 175,000 0.17 185,223 48,531
Draft fan optimization of excess air
Petroleum Jelly Installation of three tanks to reduce heat
storage tanks losses, thereby reducing steam 150,000 293,000 0.51 299,533 78,481
requirements
Hot water Installation of a condensate recovery line
production to allow collection of condensate from hot 2,000 35,000 0.05 28,577 7,488
water production

Reverse Installation of the reverse osmosis water

osmosis plant storage tank and recovery of condensate
from the concentric pipe heat exchange 120,000 485,000 0.26 439,244 115,087
used to heat the water

Boiler feed Installation of the hot well used to store

water system returned condensate and make- up water 80,000 90,181 0.88 185,223 25,008

Steam Repair passing steam traps and steam

78,481
distribution leaks 209,000 0.51 299,533
system
(1 ZAR = 0.217 ILS)
The SSO Training Programme
The SSO Training Cycle

• 1 day introductory workshop

• 2 day user training
• Expert training
• Individual assessment
• Final examination
• Graduation
The SSO User Training Programme

Why should people attend? What can people expect?

• Structured class room based training

• Save the company money
on the fundamentals of efficient
• Personal development
steam systems
• Internationally accepted assessment
• To learn about user level interventions
methodology
that can be applied at the work place
• Accredited qualification

What is required of participants? Who should attend?

• Engineers and technical staff

• Engineering / technical background
• Managers and supervisors
• Willingness to implement theoretical
• Government agencies
concepts
• University personnel
• Total of 16 hours spread over 4 days
• Anyone involved in sustainability
The SSO Expert Training Programme
Why should people attend? What can people expect?

• Save the company money • Structured training programme

• Personal skills development • Combination of class room and
• Internationally accepted assessment mentored experiential learning
methodology • Practical individual assessment with
• Accredited qualification full support from international trainers

What is required of participants? Who should attend?

• Engineers and practitioners intending

• Engineering / technical background
to become steam system
• Access to a suitable site for practical
assessment practitioners
experiential learning
• Persons who would like to become
• Total of 15 days spread over 8 months
UNIDO system trainers
SSO Certification Options

• For participants who are interested in steam

systems and would like to increase their
Attendance
general knowledge
Certificate
• Attendance of at least 75% of total course

• For participants who intend to become active

practitioners in the assessment of industrial
Expert
heat systems including steam systems
Certificate
• For participants who would also like to
become UNIDO trainers and facilitators
SSO Expert Certificate

Requirements:
• Attend the User training (2 day).
• Write and pass the User training class test achieving at least 70%.
• Attend the Expert training (5 day).
• Actively participate in the class discussions, practical demonstrations and
presentations.
• Complete an individual steam system assessment at an industrial plant.
• Attend progress webinars as arranged.
• Write and pass a final examination based on the coursework covered,
obtaining a minimum pass mark of 70%.
• Obtain an overall final pass mark of 70% based on the individual report, final
examination and class participation.
SSO Trainers and Facilitators

Purpose
• To enable continued transfer of knowledge
• Local capacity building for self sustainability

Requirements
• Training skills – ability to engage and communicate with participants in a
learning environment
• Knowledge – of subject matter, ability to think critically, analyse challenges
and synthesise solutions,
• Attitude – professional conduct and behaviour couple with ethics and values
regarded by UNIDO
• Qualification – technical / mechanical background
Discussion & Questions
Next steps…

• Complete feedback forms

• Register for CASO User Course (coming in 2021)

Become part of the energy

family by becoming an
expert in compressed air
systems optimisation
For more information

Please contact the following email:

[email protected]

www.moustadama.ps
 Thank You!

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