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CONDENSATE & FLASH RECOVERY SYSTEMS
Recovery of the Energy in Flash Steam

Condensate pipe carries approximately 90% (by volume) of flash steam, and 10% of condensate. This bi-phase condition occurs immediate downstream of the trap or discharge orifice. To recover the flash steam, the bi-phase fluid has to be separated into condensate and flash steam. As the pressure is low, the separation method cannot allow much pressure drop, but must separate the two phases efficiently, so that the flash steam is dry enough to use.

Some Major Uses Of Flash Steam
  • Heating of feed water with the help of flash steam generated from boiler blow down. In continuous blow down system, especially where blow down rates are high as a result of poor feed water quality, Flash Separators can be used to recover energy from blow down. This can improve boiler efficiency substantially, and increase the steam generation of the boiler. (Every 6 degree C rise in feed water temperature results in 1% fuel saving.)
  • Using as Low pressure steam in L. P. Heater battery from the flash generated of the condensate of H. P. Heater battery.
  • Using as Low pressure steam along with high pressure steam (By using thermo compressors) for processes to bring down the consumption of H. P. Steam.
    For Example -
    1) Paper machines
    2) Solvent extraction plants.

Calculation of Flash Steam Generation

% Flash Steam Generated = (hf1 – hf2) x 100%
hfg2
Where,
hf1 = Enthalpy of water at the higher pressure in Kcal/Kg
hf2 = Enthalpy of water at the flashing pressure in Kcal/Kg
hfg2 = Latent heat of vapourisation at the flash steam pressure in Kcal/Kg


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