Technical Guide

Condensate Recovery
System
Steam Traps are essentially valves which differentiate
between steam and condensate. They open to discharge
condensate, but do not allow steam to escape. A steam
trap has three important functions:

To remove the condensate formed either within the

steam pipework or within the process equipment.
To prevent large amounts of steam escaping.
Dearation Tank To enable any air and other gases in the system to
What is it? (Image courtesy of Amarinth) escape.
Figure 2. Ball Float Steam Trap
Condensate Recovery Systems are specifically designed
equipment to recover condensate from steam
installations in order to maximise their overall energy
efficiency.

Condensate Recovery Systems equipment are

considered to include the following:

Condensate Recovery Vessels

These are designed to handle hot condensate, which is
commonly returned for use as boiler feedwater.
(Image courtesy of Spirax Sarco)
Steam Traps
Are devices which allow the
discharge of condensate In a Deaeration Tank boiler feedwater is trickled down
without the release of steam over perforated plates, low pressure steam is passed
from steam lines in a steam and upwards to strip off oxygen and other dissolved gasses.
condensate system. The steam and gas rise to the top of the tank and are
then vented to atmosphere.
Deaeration Tanks
Remove oxygen and other In another type of deaeration tank low pressure steam is
dissolved gasses from steam injected into the stored feedwater again the steam and
boiler feedwater to reduce Steam Trap gas rise to the top of the tank and are then vented to
corrosion and improve (Image courtesy of Spirax Sarco) atmosphere. Depending on the size of the installation
efficiency in the steam system. the deaeration tank also acts as the feedwater storage
tank.
How does it work? Figure 3. Dearation Tank

A Condensate Recovery Unit is a Figure 1. Condensate

Recovery Unit
vessel which receives condensate
from all practical points in a
process plant or heating system
where condensate is produced.
The vessel stores the condensate
and mixes it with fresh make up
water prior to it being used as
boiler feedwater.
(Image courtesy of Spirax Sarco)

(mage courtesy of Spirax Sarco)

What are the energy saving benefits?
Installing energy efficient technologies on an existing
standard steam and condensate installation is a means
of improving boiler performance without having to
replace the entire steam boiler or system.
Typical Energy savings for each of the technologies are
listed below:
Condensate Recovery Vessels
6 8% reduction in fuel costs
Typical payback periods 1 - 4 years
Reduced carbon emissions
Steam Traps
2-3% reduction in fuel costs
Typical payback periods 2 - 4 years
Shorter start-up times
Reduced carbon emissions
Deaeration Tanks
1-2% reduction in fuel costs
Typical payback periods 4 - 6 years
Reduced risk of corrosion failures
Reduced water treatment costs
Reduced carbon emissions
Issues to consider when choosing a Condensate
Recovery System:
Condensate Recovery Vessels
a) Where very long pipe runs would be required
to return condensate to the boiler house,
condensate recovery may not be viable in
energy terms.
b) Even where long pipe runs make energy recovery
uneconomic condensate recovery may still be
viable when the water treatment costs and
water replacement costs are taken into account.
c) If the condensate can be contaminated by
contact with process materials it can cause
fouling of the heat transfer surface in the boiler.
In such circumstances the condensate should
Wilton Park House, Wilton Place, Dublin 2
Teach Phirc Wilton, Pls Wilton, Baile tha Claith 2
be passed through a heat exchanger to recover
heat energy.
Steam Traps
a) It is essential to select the correct size and type
of trap for both starting and normal operating
loads. It is particularly important to size the trap
to accommodate the increased condensate
capacity at start-up, an incorrectly sized trap
may not operate correctly and start-up times are
likely to increase.
b) Trap sizing is based upon
- normal operational load
- (kg/h of condensate)
- start-up load
- (kg/h of condensate)
- Condensate temperature (max/min)
- Steam Pressure (max/min)
- Back pressure the trap must operate against
c) Consult a reputable manufacturer for specific
design and installation information.
d) All types of steam trap fail if they are not properly
maintained or protected. The best method for
ensuring correct trap operation and efficiency is a
planned preventative maintenance programme.
e) Failure monitoring of steam traps notifies user
when a steam trap has failed.
Deaeration Tanks
a) Sufficient space has to be available within or
near to the boiler house to accommodate the
deaeration tank.
b) Deaeration must be used in conjunction with
other water treatment measures.
c) Monitoring of the water condition must be
carried out regularly, automatically or by
sampling.
Energy efficient Localised Steam Generator Systems
are eligible for the ACA (Accelerated Capital Allowance)
and included on the Triple E product register. More
information can be found at www.seai.ie/Your_Business/
Triple_E_Product_Register/
T. +353 1 808 2100 info@seai.ie The Sutainable Energy Authority of Ireland is partly
financed by Irelands EU Structural Funds Programme
F. +353 1 808 2002 www.seai.ie co-funded by the Irish Government and the European
Union.