Energy savings from steam losses on an oil refinery

Abstract A study of steam and condensate utilisation on a refinery has been undertaken. Based on the total amount of steam produced on the plant approximately 36% was being returned to the system as condensate. Since 75% should be returned, a large quantity of steam and condensate was being lost. A total of 7100 kg h−1 condensate and steam losses were detected of which 5450 kg h−1 were condensate losses. Nevertheless, in financial terms, the economic losses are greater due to the 1650 kg h−1 of steam being lost. A survey of the plant to locate and measure losses, showed that the major part of the total loss could be attributed to a small number of large steam or condensate leaks. The loss of steam due to malfunctioning of steam traps has been considered and 25% were found to be passing live steam. Heat losses from condensate pipes were measured and the economic justification for lagging the pipes is considered. Finally, efficiency tests were carried out on the main boiler which had an efficiency of 80%. In economic terms a financial saving of over £ 121 500 per year is attainable based on the results of this investigation.