Steam System Optimization: A Case Study

Abstract

This paper highlights the study findings in a steam system in a plant from a multinational Petrochemical giant in an European country. The steam system operates with an annual budget of $8.9 million (local currency was converted to US Dollars). Normal steam demand ranges from 500,000 to 600,000 lbs/hr. 380,000 lbs/hr is imported from an outside power plant and 170,000 lbs/hr is internally generated as waste heat recovery. The steam system analysis identified energy savings worth of $2,400,000 per year. The optimization measures were in two categories: • no cost / low cost that can be done through better maintenance and improvement of operating conditions. • major improvement that requires a significant amount of investment, that includes the modification of process and major equipment. Though the findings are specific to a single site, the basics of steam system analysis are applicable to any steam system. A critical review on any steam system always identifies controllable wastes. Improvements in steam system efficiency equal reduced energy consumption and saved environment.