Reduction in Fuel Consumption and CO₂ Emissions by Elimination of Steam Leak from Steam Traps

Abstract

Steam traps are automatic mechanical valves installed in the steam distribution system (SDS) of various process industries. The steam traps operate to discharge condensate, air, and other impurities that reduce the efficiency of the steam lines. Generally during the maintenance of the SDS, the steam traps are neglected as they are placed in locations which are not easily approachable. But if steam traps are not working properly, they result in huge loss of energy as they are in large quantity in the SDS. With the increasing energy crisis and global warming, there is an urgent need to save each bit of energy and reduce green house gas emissions. The main purpose of the present study is to reduce the energy consumption needed to produce steam by decreasing the losses of the steam traps installed in the SDS. The sight method and temperature measurement method have been employed to detect the losses and working of steam traps. Further, the Masoneilan’s formula has been used to quantify the steam saving from a leaking steam trap. The results of the present research for a typical textile industry show that the annual wastage of steam through leaking steam traps amounts to 450 tonnes. Thus, if the wastage of steam is stopped, this would result in saving of 115 tonnes of rice husk (fuel) which amounts to saving of Rs. 4 Lakhs per annum. Due to this savings, there will be a reduction of 189 tonnes of CO₂ emissions per annum to the environment.