maxiflo® ejector system an innovative approach to steam ... region/maxiflo presentation.pdf ·...
TRANSCRIPT
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MAXIFLO® EJECTOR SYSTEM
AN INNOVATIVE APPROACH
TO STEAM CONSERVATION
LEVEL 4 BEEACCREDITED
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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%.
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CONDENSATE
REMOVAL SYSTEMS
PART 1
Condensate removal with
steam traps.
PART 2
Condensate removal with the
Maxiflo® ejector system.
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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.
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COMMON TYPES OF
STEAM TRAPS
• Inverted Bucket Trap
• Float & Thermostatic Trap
• Thermodynamic Trap
• Thermostatic Trap
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INVERTED BUCKET
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FLOAT & THERMOSTATIC
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THERMODYNAMIC TRAP
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THERMOSTATIC TRAP
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DISADVANTAGES OF
STEAM TRAPS
• They require regular testing &
maintenance to operate efficiently.
• Different types of traps require different
test equipment and procedures.
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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.
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THERMAL IMAGES OF STEAM
TRAPS ON SIMILAR APPLICATIONS
Failed open Working order
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ACTUAL FAILED TRAPS
• Trap internals eroded from steam blow.
• Ball floats damaged from waterhammer.
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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 63 000 per year in steam loss.
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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.
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MAXIFLO® RANGE
• 15, 20, 25, 40 & 50 mm Nominal Bore
• Screwed, Flanged, Socket weld or Wafer
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MAXIFLO® SYSTEM
• Has no moving parts.
• Stainless steel construction.
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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…
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THE DENSITY OF STEAM
COMPARED TO CONDENSATE
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• The turbulent condensate discharge through the
ejector effectively “blocks” the steam passage.
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.
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THEORY CONFIRMED BY THERMAL
IMAGE OF MAXIFLO®
The continuous discharge of condensate (maroon)
holds the steam (yellow) back in the line.
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EXAMPLE OF MAXIFLO® ON A
CORRUGATING ROLL
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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…
MAXIFLO® DISCHARGE
CHARACTERISTICS
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In 1 hour, all the condensate discharged through the ejector,
but only 6.5 % of the steam was able to discharge.
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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.
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DECLARED STEAM LOSS FROM TRAPS IN
WORKING ORDER (BY MANUFACTURERS)
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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
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MAXIFLO® IN OPERATION ON
CORRUGATING ROLL
• Kinetic energy from the exhaust steam
accelerates the condensate discharge.
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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.
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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.
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PRIMARY SAVINGS:– MAXIFLO REDUCES
AIR AND CONDENSATE BARRIERS
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THE EFFECTS OF AIR AND CONDENSATE
BARRIERS TO HEAT TRANSFER
• Reducing air and condensate barriers
improves thermal efficiency by up to 20%
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SECONDARY SAVINGS:– MAXIFLO
DOESN'T WEAR AND FAIL OPEN
• As moving parts wear, steam loss from traps
increase progressively, until total failure.
TYPICAL STEAM LOSS TABLE AT 10 BAR
LIFE SPAN TYPICAL STEAM
TRAP LOSS
MAX. PERMISSIBLE
MAXIFLO LOSS
1st year 2.5 kg/hr 2.5 kg/hr
2nd year 3.5 kg/hr 2.5 kg/hr
3rd year 7 kg/hr 2.5 kg/hr
20 years 7 - 50 kg/hr 2.5 kg/hr
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ADVANTAGES OF MAXIFLO®
• Proven life span over 20 years.
• Results in sustainable steam savings.
• Improves efficiency of equipment.
• Requires only low maintenance.
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BENEFITS OF TOTAL PLANT CONVERSION
• Steam savings of 15% - 30% achieved.
• Improved performance of process equipment.
• Reduced steam trap maintenance.
Before Maxiflo After Maxiflo