Efficient steam utilisation through advanced flow measurement technology
3 ways how KROHNE can optimise your steam utilisation
Precise flow measurement with Vortex technology
Energy flow monitoring with integrated energy calculators
Real-time data and anomaly detection
Maximising the efficiency of steam as an energy carrier
Steam remains one of the most efficient energy carriers in industrial operations, widely used across a variety of sectors such as chemicals, food and beverage, and pharmaceuticals. Steam and green steam are often generated in external combined heat and power (CHP) plants or on-site industrial steam plants, with energy sources ranging from natural gas to biomass or even production residues. In many cases, backpressure turbines are employed to produce electricity, with the leftover steam being repurposed for plant operations.
However, given steam’s high energy content and cost of production, it is essential to ensure that its use is optimised. This is where KROHNE’s advanced differential pressure (DP) flow measurement, vortex flowmeters, and ultrasonic flowmeters play a vital role in monitoring steam flows and distribution. These technologies help industries achieve maximum efficiency and unlock significant sustainability potential by reducing waste and ensuring energy is used as effectively as possible.
How does it work?
The key to efficient steam usage lies in precise and continuous monitoring of steam flows. KROHNE offers multiple technologies for this purpose, including:
Differential Pressure flow measurement (DP-flow): This well-established technique involves measuring the pressure difference across a primary element like an orifice plate, venturi tube, or nozzle to calculate the flow rate. DP-flow systems are accurate and reliable for steam measurement across a wide range of conditions, as well as being highly versatile and based on established standards such as ISO 5167 and ASME MFC-3M.
Vortex flowmeters: These meters measure the vortices created as steam flows past a bluff body, offering a cost-effective solution with no moving parts, which makes them ideal for demanding industrial environments. Furthermore, they accurately indicate the steam state (wet, saturated or superheated) and thus help optimise the operation of the steam supply by avoiding condensate accumulation and inefficient steam use.
Ultrasonic flowmeters: Ultrasonic technology provides non-invasive flow measurement by transmitting sound waves through the steam. This highly accurate method is particularly suitable for large pipes and high flow rates, and it ensures minimal maintenance over the instrument's lifecycle. They also have a high flow turndown, can be operated bi-directionally and have long-term stability.
Combining these technologies provides operators with a comprehensive view of steam usage, enabling precise control and efficient distribution across plant processes.
How can KROHNE help you?
Precise flow measurement with Vortex technology
KROHNE’s OPTISWIRL 4200 provides accurate measurement of steam flows, ensuring that steam is distributed efficiently throughout the plant. By continuously monitoring flow rates and heat flows at elevated temperatures and pressures, the system prevents the overuse of steam, optimising energy distribution and reducing unnecessary production.
Energy flow monitoring with integrated energy calculators
With built-in heat calculators and integrated temperature and pressure sensors, the OPTISWIRL 4200 monitors total energy flows, including both steam supply and condensate return. This allows operators to identify inefficiencies in steam utilisation, helping them make data-driven decisions to improve overall energy efficiency and reduce waste.
Real-time data and anomaly detection
KROHNE’s system provides real-time data to the control room, allowing operators to monitor steam usage continuously. Any deviations in steam distribution or energy consumption can be identified immediately, ensuring that corrective actions are taken promptly. This minimises energy loss and keeps the steam utilisation at optimal levels.
Contribution to Sustainability
Energy efficiency and cost reduction : Steam is a valuable resource, and even slight measurement inaccuracies lead to energy loss and cost. KROHNE’s flowmeters ensure precise usage, preventing inefficiencies.
Waste reduction : Accurate measurements identify leaks, insulation issues, and inefficient equipment, enabling actions that cut energy waste and reduce environmental impact.
Optimisation potential : Real-time steam monitoring across operations highlights optimisation opportunities, enabling more efficient steam distribution and sustainable energy management.
Further benefits
Reduced energy costs : Efficient steam distribution lowers energy consumption and associated costs.
Minimised downtime and maintenance costs : Real-time data reduces unexpected failures, cutting maintenance costs and downtime.
Extended equipment lifespan : Improved steam management prevents overuse, extending the life of critical equipment and reducing replacement costs.
Optimised resource utilisation : Efficient steam usage reduces fuel needs, lowering long-term operating expenses.
Achieving sustainability goals with KROHNE
Optimising steam use is key to reducing costs and environmental impact. KROHNE’s flow measurement solutions enable accurate steam monitoring, supporting plant-wide energy efficiency. With advanced technologies like DP-flow, vortex, and ultrasonic flowmeters, KROHNE helps industries transition to sustainable practices, minimising waste and driving operational excellence. Designed to meet specific application needs, KROHNE’s solutions ensure reliable and efficient steam management, contributing to both financial and environmental sustainability.