The flash steam separator is a vessel that allows you to get low pressure steam from superheated water (condensate).
As a result, usable low-pressure steam and steam-cooled low-grade condensate are formed at the separator outlet.
The Flash Steam Separator (AFVV) is widely used in enterprises where there is steam of two pressures: high pressure steam (as the main one) and low pressure steam.
It is most expedient to use secondary energy resources (flash steam) for technological purposes. It is also possible to use flash steam obtained from industrial condensate using a steam jet compressor.
Condensate heat can also be used for heat supply purposes: heating and ventilation systems, hot water supply for industrial and sanitary heat consumers.
Some use cases:
Corrugators
Cardboard making machines.
Paper-making machines.
Continuous blowdown of steam boilers.
Evaporation plants.
Textile industry (for example, drying linen).
Multistage steam-air heater.
Manufacture of car tires, rubber products.
Various heat exchangers using high pressure steam.
The flash steam separator belongs to the category of energy-saving. Its use is justified in many cases when it comes to the possible use of low-temperature secondary thermal resources that provide direct fuel savings.
The use of a flash steam separator (OPVV) allows:
Get low pressure steam for reuse.
Save fuel for a fraction of low pressure steam generation.
Reduce losses associated with high flash volume.
Increase % condensate return.
Improve the environmental performance of the enterprise by reducing fuel combustion and reducing vaping.
Heat exchangers of industrial enterprises, depending on the nature of the technological process, consume steam of various pressures (3 - 15 bar). Therefore, the condensate discharged from the apparatus has a saturation temperature of 130 - 190 C, its enthalpy is 560 - 815 kJ / kg.
The enthalpy of condensate can be even higher if we take into account that a certain amount of so-called "flying steam" breaks through leaks in steam traps. Depending on the type of steam traps, their correct selection and condition, the amount of "pass steam" is about 0.5 - 20% of the amount of steam in the heat exchanger.
In open condensate collection systems, the condensate, entering the collection tank, partially evaporates. For the above parameters of condensate when it boils in a tank communicated with the atmosphere (open condensate collection systems), the amount of flash steam formed is 6 - 18% of the condensate flow rate. On average, this amounts to a heat loss of about 320 kJ per 1 kg of condensate.
In closed condensate collection systems, hot condensate, if it is not cooled, will immediately equalize the pressure in the condensate tank and in the heat exchanger, which is unacceptable due to the mechanical strength of the tank.
Thus, both in open and closed condensate collection systems, it is necessary to lower the temperature of the condensate entering the collection tank to 100C. The flash steam trap solves this problem perfectly.
The payback period of any energy-saving equipment depends on the workload of this production line and the enterprise as a whole. Therefore, the payback period is always calculated individually.
But, in the context of rising energy prices, even with an average workload of the enterprise, the payback period
the steam separator itself does not exceed 3 months.
When using a flash steam separation station, the payback period can be 4-8 months.
The payback period is significantly reduced when:
— high loading of the technological line;
— high productivity of the technological line;
- operation of the line with high pressure of live steam.
Advantages :
1. The specially made design of the apparatus ensures good separation of the phases into vapor and liquid, first by creating a thin film of the vapor-condensate mixture, and then by good mixing of the mixture in the body itself. This ensures maximum effervescence and maximum steam recovery. Thus, the device will separate the steam as much as possible and cool the condensate.
2. The presence of a built-in separation device will provide dry steam. The special design of the mesh separator allows you to adjust the degree of steam dryness by changing the density of the separator itself. This solution allows to significantly reduce the steam consumption for a further consumer by reducing the thermal condensate film. It also reduces the amount of newly formed condensate, leading to water hammer, erosion of steam lines and equipment.
3. The design of the separator also provides for the purification of the flash steam from impurities, acting as a built-in filter.
4. The design of the apparatus is made collapsible. This makes it possible to inspect the inside of the housing, and also allows the separator to be cleaned from contamination or replaced.
5. The separator itself is made of stainless steel, which ensures a long service life in conditions of increased droplet entrainment at high speeds.
