Sustainable energy management through steam and condensate flow monitoring
3 ways how KROHNE can support your steam and condensate utilisation
Optimising energy flows with steam and condensate monitoring.
In industries where steam is essential, such as chemical manufacturing, food processing, and power generation, efficiently managing steam and condensate is crucial for both operational efficiency and sustainability. Steam, a highly effective energy carrier, must be carefully monitored to prevent energy loss and maintain optimal process efficiency. Equally critical is the recovery of condensate, which carries valuable residual heat that can be recycled, reducing costs and environmental impact.
KROHNE’s OPTISWIRL 4200 flowmeter provides an advanced solution for monitoring steam and condensate flows, helping facilities optimise energy usage. This vortex flowmeter offers precise, real-time data on steam and energy flows, empowering operators to enhance energy management and support their sustainability objectives.
Example calculation: Energy savings through optimised steam and condensate monitoring
Consider a facility that processes 1,000 kg of steam per hour. If optimised monitoring reduces steam loss by just 5%, this translates to a saving of 50 kg of steam per hour. Assuming the energy cost per kg of steam is €0.02:
Hourly savings: 50 kg × €0.02 = €1.00
Daily savings (assuming 24-hour operation): €1.00 × 24 = €24.00
Annual savings (assuming 300 operational days per year): €24.00 × 300 = €7,200
This example illustrates how optimised steam and condensate monitoring with the OPTISWIRL 4200 can result in substantial annual energy savings, demonstrating the significant financial and sustainability benefits of precise monitoring.
How does it work?
The OPTISWIRL 4200 utilises the vortex principle to measure steam flow, creating swirling vortices as steam passes a bluff body inside the meter. The frequency of these vortices is directly proportional to the flow rate, enabling accurate measurements even in high-temperature and high-pressure conditions, making it ideal for industrial steam applications.
In addition to flow measurement, the OPTISWIRL 4200 integrates advanced features for complete energy management. Equipped with a built-in energy calculator and integrated pressure and temperature sensors, it provides precise heat flow calculations. When paired with a secondary temperature sensor on the condensate return line, it enables full-cycle monitoring—capturing both the energy delivered via steam and the heat recovered through the condensate, creating a comprehensive view of energy flows. In addition, all energy measurements can be performed with a single multivariable device, reducing engineering and installation effort throughout the process.
Enhanced energy auditing
The OPTISWIRL 4200 provides precise flow data for steam and condensate, which supports comprehensive energy audits. By identifying peak usage times and areas of high loss, operators can make targeted adjustments that reduce energy costs and improve process efficiency.
Reduction of downtime
Real-time monitoring allows for early detection of irregularities in steam and condensate flows, which can indicate system wear or leaks. Early intervention prevents larger issues, reduces unplanned downtime, and cuts overall maintenance expenses. Additionally, maintenance schedules can be based on actual usage patterns, extending equipment life and ensuring consistent performance.
Improved process control
With accurate steam distribution data, the OPTISWIRL 4200 enables precise control of steam flow, which is essential for maintaining stable process temperatures and product quality. This not only supports product consistency but also allows operators to make quick adjustments to adapt to production changes, maximising the efficiency of energy-intensive processes.
Contribution to Sustainability
Effective steam and condensate flow monitoring have significant implications for sustainability, providing multiple opportunities for energy optimisation:
Optimised steam distribution : By accurately tracking steam usage, the OPTISWIRL 4200 ensures that only the necessary amount of steam is supplied to each process stage. This reduces overproduction and minimises energy waste, leading to more efficient resource use.
Complete energy flow visibility : By monitoring both steam and condensate flows, operators gain a full picture of energy use, allowing them to pinpoint inefficiencies
Lower environmental impact : Enhanced steam efficiency and condensate recovery translate directly into reduced energy consumption and lower greenhouse gas emissions, helping facilities move towards greener operations while cutting operational costs.
Further Benefits
Reduced fuel and energy costs : By optimising steam and condensate flows, facilities use less fuel for steam generation, directly lowering energy costs.
Lower maintenance expenses : Detection of steam in its wet, saturated or superheated state, resulting in an efficient and safe operation of the steam grid. Proper monitoring helps reduce strain on equipment, leading to fewer breakdowns and lower maintenance costs.
Enhanced lifecycle of equipment : Minimised thermal stress on equipment through balanced energy flows helps prolong the lifespan of assets, reducing capital expenditure over time.
Achieving sustainable operations with KROHNE
KROHNE's OPTISWIRL 4200 is designed to meet the increasing demands for energy efficiency and sustainability in industrial environments. With its advanced steam and condensate flow monitoring capabilities, it enables precise control of energy consumption, minimising waste and increasing production efficiency.
The real-time data provided by the OPTISWIRL 4200 supports better decision-making, enabling operators to optimise both steam generation and condensate recovery. This comprehensive approach to energy management helps facilities maximise resource efficiency, fostering sustainability without compromising operational performance.