Thermodyne Engineering Systems
Optimizing Steam Supply for Laminate Manufacturing Plant
Client: Laminate Manufacturing Plant
Industry: Laminates
Problem: Steam Pressure Drop During Laminate Press Operation
Solution: Installation of a Steam Accumulator
Result: Improved Productivity and Enhanced Boiler Efficiency
Overview
A leading laminate manufacturing plant was using a 6 TPH (ton per hour) steam boiler to support its production processes, particularly the laminating press. The plant was experiencing a significant steam pressure drop during the press operation, which required a sudden surge of steam. This pressure fluctuation affected the laminate quality and reduced productivity. Initially, the company planned to invest in a larger 12 TPH boiler to address the problem, but our team proposed an innovative and more cost-effective solution.
Our Approach
Upon a detailed analysis of the plant’s steam consumption, we discovered that the average steam load was only 5000 kg/hr, which the existing 6 TPH boiler could handle comfortably. The pressure drop was due to the sudden “jerk load” during press operation, not an overall deficiency in boiler capacity.
To address this, we proposed installing a steam accumulator:
- Steam Accumulator Function: The steam accumulator would store excess steam during periods of lower demand (idle cycles) and release it during peak demand (jerk load), effectively smoothing out the steam pressure and eliminating fluctuations.
Solution Implementation
- Data Collection and Analysis: We collected real-time steam usage data for each production batch and identified the peak load during the press operation.
- Proposed Solution: Instead of installing a new, larger boiler, we recommended the installation of a steam accumulator. This would:
- Store excess steam when the demand is lower.
- Provide additional steam during the high-demand “jerk load” periods of the laminating press.
- Implementation: The steam accumulator was integrated into the existing boiler system without requiring major modifications.
Results
- Stable Steam Pressure: The steam accumulator effectively mitigated the pressure drops by equalizing the steam load, ensuring consistent steam supply during press operations.
- Improved Productivity: With stable steam pressure, the plant was able to increase its productivity, raising the number of batches produced from 18 to 22 per day.
- Cost Savings: By optimizing the existing 6 TPH boiler with a steam accumulator, the plant avoided the substantial cost of installing a new 12 TPH boiler.
- Enhanced Laminate Quality: Consistent steam pressure resulted in better laminate quality, as the laminating process was no longer disrupted by pressure fluctuations.
Conclusion
By understanding the root cause of the pressure drop and proposing the use of a steam accumulator, we helped the laminate manufacturing plant achieve both operational efficiency and cost savings. The solution not only eliminated the need for a new boiler but also significantly enhanced productivity, ultimately contributing to the company’s overall growth.