Return of the couple in the brazier
Sunflower oil production is a fairly profitable business. This allows you to turn a blind eye to a certain unevenness of technical processes, because the profit still covers the costs. However, one of the oil extraction plants, seeking to increase margins, nevertheless optimized costs, in particular for energy resources. The water vapor that heats the seeds in the braziers is a valuable resource, as it consumes now precious gas or other fuel. We proposed, developed and implemented an economical system for returning secondary boiling steam back to the production cycle, and condensate to the boiler room. The direct savings from this solution alone are more than 15,000 euros annually. And then there are the accompanying process improvements that cost even more!
Need
To roast sunflower seeds in braziers, water vapor is used - an expensive and valuable resource. It is obvious that the ways of energy saving were searched for here. At the same time, it was a strict requirement not to aggravate the technological process. After implementation, it turned out that those. the process stabilizes better, and besides the obvious savings, other benefits are obtained.
Water vapor through the vats gives off its energy to the product in the brazier and condenses. The condensate still contains a significant amount of usable energy. Getting into the low pressure zone, under the atmosphere, it boils again and forms the so-called secondary boiling pair. In most cases, this energy is not reused. Huge puffs of steam on the sites of the enterprise - this is it. Energy that has already been paid for.
Fig.1. Fragment of the complex Return of the couple in the brazier – installations for the collection and return of condensate
The reuse of such a pair in the technological process leads to a reduction in the cost of steam production by 5 ... 15%. In addition, the percentage of condensate returned increases, which leads to a decrease in the amount of water for feeding the system and a decrease in the cost of its preparation.
implementation results
| Result | Benefit |
| Reduction of consumption of live steam and increase in the percentage of return of condensate with a higher temperature | Direct savings on steam generation (up to 15%):
- lower fuel costs - water, - chemicals for water treatment |
| Product quality improvement | The regulation of the first group made it possible to improve the mass fraction of phosphorus-containing substances in oil, in terms of stearoleolecithin, from 0.8 to 0.66. |
| simple control | The interface is very simple - an operator of any age and qualification can handle it. Automation itself will select the desired mode and monitor the progress of the process.
At the same time, the interface is modern, web-based, which appeals to the younger generation. Easier to recruit them |
| Pair is used to the maximum | There is evaporation on the site, ice does not grow in winter - safe working conditions |
| The increase (in acceptable norms) of the temperature of those. process or installation performance | We got a deeper heating of the material and a low moisture content of the product. At the same time, automation controls and keeps the temperature within the specified limits.
Performance gain - up to 5% |
| Replacing the scheme "for Steam Traps" with our development | A flying acute pair, diagnosed only with special devices, could quietly fly out “down the pipe” for weeks. Now it's impossible. And in general - there are no steam traps - there is no need for maintenance and problems with it. |
| Clear self-diagnosis | The operator, when he suspected a steam trap failure, simply opened the bypass and forgot it. Now the system reports problems in the nodes, their possible causes and solutions |
| Convenient reporting | All events that occurred parameters, operator commands are registered and saved. The responsible engineer or owner can instantly see the progress of the process for any interesting period of time. This is a good tool for debriefing and, more importantly, finding potential improvements |
| Remote monitoring and maintenance service | For reporting, you do not need to go to the site - just open a browser and go to the installation site. And, if necessary, to connect specialists in the situational center "ARTESIA" to the diagnostics. Much less time and nerves, and, consequently, money, are spent on finding and eliminating problems. |