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3.6 Reduced steam temperature Many plants can cut energy costs considerably by replacing their shell-and-tube reboilers or steam heaters with compact heat exchangers. The higher thermal efficiency of compact heat exchangers often allows you to use a lower temperature heating medium compared to shell-and-tubes. Switching to lower grade steam will cut energy costs in most cases. Example: Sour water stripper unit A refinery asked Alfa Laval to evaluate the possibilities of using lower grade steam in their sour water stripper unit. Exchanging the existing shell-and-tube for a Compabloc allowed the refinery to switch heating medium from medium-pressure steam at 180°C (356°F) to low-pressure steam at 138°C (280°F). The stripper column operates at 127°C (261°F) and Compablocs are capable of handling temperature approaches as close as 3°C (5.4°F). This means the steam temperature in this example could have been as low as 130°C (266°F). As well as cutting energy costs, the new Compabloc also had a much smaller installation footprint. Assumptions • Initial steam consumption = 14.15 metric tons/hour • Operating hours per year = 8,400 • Low-pressure steam at 3.5 bar(a) available and possible to use as heating medium in the reboiler • Cost for heat exchanger = €568,000 • Installation factor = 3 • Installed cost of heat exchanger = €1,704,000 Figure 3.19 Reduced utility temperature Payback period when switching from medium-pressure steam at 180°C (356°F) to low-pressure steam at 138°C (280°F). Pay back period (years) 7 6 5 4 3 2 1 0 0 2 4 6 8 10 12 14 16 18 20 Price difference between mp steam and lp steam (EUR/ton) 46PDF Image | Waste heat recovery Optimizing your energy system
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