Importance of Condensate Recovery in Industrial Operations “AMOC CASE”


Authors : Dr. Ibrahem Omran

Volume/Issue : Volume 9 - 2024, Issue 9 - September


Google Scholar : https://tinyurl.com/3t7ufhtt

Scribd : https://tinyurl.com/2k7ywrez

DOI : https://doi.org/10.38124/ijisrt/IJISRT24SEP1287

Note : A published paper may take 4-5 working days from the publication date to appear in PlumX Metrics, Semantic Scholar, and ResearchGate.


Abstract : Condensate recovery is a crucial aspect of industrial processes that involves the collection and reuse of condensed steam, a byproduct of heat exchange systems. This research paper explores condensate recovery's significance in industrial operations. It discusses the benefits, challenges, and best practices associated with condensate recovery, emphasizing its environmental, economic, and operational impacts. This research also examines various technologies and strategies used for efficient condensate recovery and highlights the importance of incorporating such practices into industrial settings for sustainability and resource conservation. The walk-through sample survey for the Scoping study of Steam Traps & condensate recovery system was carried out at AMOC, plant from 24th Dec-2017 to 26th Dec-2017. the audit study was in a total number of 4675 steam traps, the result of the audit found 50% failure of these traps. AMOC consists of a lube oil complex and a gas oil complex with tank farms and a utilities section, 1st stage of the study was finished in the lube oil plant with [1] Total Savings Potential (in USD) = 234745, [2] Total Investment (in USD) = 245521, and [3] Total Payback for the System = 12.5 months.

References :

  1. Arora, Amit, et al. "Optimization of condensate recovery system in a process industry." International Journal of Energy Research, vol. 45, no. 7, 2021, pp. 11073-11086.
  2. Considine, Timothy, et al. "Advances in condensate recovery systems: A comprehensive review." Applied Thermal Engineering, vol. 180, 2020, 115859.
  3. Datta, Sudipta, et al. "Improving energy efficiency through condensate recovery: A case study in the chemical industry." Journal of Cleaner Production, vol. 301, 2021, 127096.
  4. Energetics Research Group. "Condensate Recovery Best Practices: A Guide for Industrial Applications." Energy Efficiency and Renewable Energy (EERE) Publications, U.S. Department of Energy, 2020.
  5. González-González, J. M., et al. "Current status and future trends in condensate recovery technologies for industrial applications." Renewable and Sustainable Energy Reviews, vol. 148, 2021, 111291.
  6. International Association for the Properties of Water and Steam (IAPWS). "Condensate Polishing: A Best Practices Guide." Technical Guidance Document, IAPWS, 2019.
  7. Liu, Wei, et al. "Integrated design of condensate recovery and utilization system for industrial boilers." Energy Conversion and Management, vol. 246, 2022, 114084.
  8. Pritchard, J., et al. "Condensate recovery for sustainable industrial processes." Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, vol. 235, no. 5, 2021, pp. 867-882.
  9. United Nations Industrial Development Organization (UNIDO). "Guidelines on Condensate Recovery in Industrial Energy Efficiency." Technical Report, UNIDO, 2018.
  10. Zhang, Li, et al. "Optimal design and operational analysis of condensate recovery systems in industrial processes." Journal of Cleaner Production, vol. 278, 2021, 123992.
  11. Forbes Marshall, 2018. Report on steam trap, condensate system audit and SCADA system on Alexandria mineral oils company “AMOC”

Condensate recovery is a crucial aspect of industrial processes that involves the collection and reuse of condensed steam, a byproduct of heat exchange systems. This research paper explores condensate recovery's significance in industrial operations. It discusses the benefits, challenges, and best practices associated with condensate recovery, emphasizing its environmental, economic, and operational impacts. This research also examines various technologies and strategies used for efficient condensate recovery and highlights the importance of incorporating such practices into industrial settings for sustainability and resource conservation. The walk-through sample survey for the Scoping study of Steam Traps & condensate recovery system was carried out at AMOC, plant from 24th Dec-2017 to 26th Dec-2017. the audit study was in a total number of 4675 steam traps, the result of the audit found 50% failure of these traps. AMOC consists of a lube oil complex and a gas oil complex with tank farms and a utilities section, 1st stage of the study was finished in the lube oil plant with [1] Total Savings Potential (in USD) = 234745, [2] Total Investment (in USD) = 245521, and [3] Total Payback for the System = 12.5 months.

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