Condensate Polisher Shipped to Canada

Recently, we shipped a sodium cycle condensate polisher to Ontario, Canada for a combined cycle power plant.  The system was constructed entirely of 304 stainless steel.

Sodium Cycle Condensate Polisher for Ontario Power Plant

The features of this system include:

Company	Combined Cycle Power plant
Water Treatment Application	Condensate Polisher to scavenge trace hardness and iron from returning condensate
Savings and/or ROI	Loss Prevention keeping heat transfer surfaces clean and reliable for years of trouble free operation
Operating Conditions	Return Condensate flow rate is between 30-90 gpm
System Configuration	24” diameter Simplex
Materials Of Construction	304 Stainless Steel, CRN code stamped pressure vessel
Piping Construction	All Welded and Flanged Face 304 Stainless Steel piping
Type Of Valves And Actuators	All Bray valve Lug style-  150 ANSI flanges
Control Philosophy	Customer supplied their own PLC panel. Res-Kem supplied the enclosure with DIN rail mounted solenoids. Enclosure also had room for customer supplied HMI
Options	CRN code stamped pressure vessel Sub-surface wash

 

304 Stainless Steel Sub-Surface Wash and Hub and Laterals Distributors

 

Condensate Polisher Shipped to Michigan

A condensate polisher for a district heating plant in Michigan was shipped last week. 


Dual Skid-Mounted Condensate Polisher for District Heating Plant in Michigan

Customer:	Utility District Heating
Water treatment application:	Condensate Polisher to scavenge trace hardness and iron
Expected savings:	Loss prevention keeping heat transfer surfaces clean and reliable for years of trouble free operation
System configuration:	Dual Parallel. On-Board Controller has a relay to indicate start and stop of regeneration process on each polisher vessel. The plants in house DCS system then ramps down the flow rate to each condensate polisher based upon regeneration schedule and times
Materials of construction:	Pressure vessels are 304 stainless steel with 125 psig ASME code stamped All face piping is welded and flanged Schedule 40 SS 304ss welded to B31.1 standards
Valve and actuators type	All automated valves are Bray valve Lug style for 150 ANSI flanges. Actuators are Bray pneumatic.
Control philosophy:	The utility didn’t want to reinvent a control scheme within their DCS, so the off the shelf controllers are being used locally to control both units. System parameters like individual tank flow and regeneration status are outputted to the plants DCS system.

For Additional Information:
Condensate polisher bulletin
Rental condensate polisher bulletin
Condensate polisher portfolio page
Boiler feed water checklist

Condensate Polisher Shipped to New Jersey University

Last week, Res-Kem shipped a condensate polisher to a New Jersey university.  This condensate polisher will be installed as part of a new onsite power production facility at the university operated by an independent energy development company.  They will produce power for the university under a DBOM (Design, Build, Operate, Maintain) agreement. Excess power produced gets sold to the PJM.

Dual, Skid Mounted Stainless Steel Condensate Polisher with Headers

Customer	An independent energy development company specializing in the development, engineering, construction, start up, commissioning, operation, maintenance and management, as well as, ownership of Central Energy Centers, Renewable Energy projects and Combined Heat, Chilling and Power  Production Facilities.
General water treatment application	Two large 48”X60” sodium cycle condensate polisher for removal of contaminants in the return condensate and the return condensate from the steam driven chillers on-site
Savings and/or ROI the customer wants to achieve	Fuel and chemical saving related to the removal of iron and calcium from the condensate streams and ultimately the boiler feedwater
Operating conditions	250 gpm max, 150 gpm continuous operating at 180F
System configuration	Twin parallel / Alternating system
Materials of construction	Skid mounted 304 SS pressure vessels Schedule 10 welded /flanged face piping
Type of valves and actuators	Bray valves with Bray actuators
System Control	Allen Bradley PLC operates the system as alternating or parallel
System schematic	Polisher collectively handles two condensate streams – return condensate from campus and condensate from steam driven chillers
Special Features	Sample cooler mounted on skid which can sample the inlet and outlet of each vessel Inlet and outlet headers between each system on skid

Additional Information:
Listing of Condensate Polishers Built by Res-Kem
Online Catalog of Res-Kem Condensate Polishing Equipment
Condensate Polisher Technical Bulletin
Condensate Polisher Application Checklist 
For Technical Help From a Res-Kem Sales and Application Engineer

Dual Parallel Condensate Polisher Will Help Large New York University Prolong Life of New Boiler

A well-known university in upstate New York that was in need of a Condensate Polisher recently reached out to Res-Kem for help. Kevin Preising discusses how Res-Kem worked closely with the university’s chief engineer and another local firm to help specify and size the unit, which will help prolong the life of the university’s new boiler.
Listen now –

For Additional Information:
For help sizing a system contact Kevin Preising
CP Checklist - Web Page
CP Checklist - Printable Version
Condensate Polisher Bulletin
View our Condensate Polisher Portfolio

Water Softener vs. Condensate Polisher – Knowing the Differences Can Help you "Get Greener"

Many companies are on a constant quest to run their business in the most energy-conscious, money-saving way possible. For those whose operations involve a low-pressure boiler system environment, investing in a condensate polisher is one of the easiest ways to “get greener” through energy efficiency and dollar savings.

In most every boiler plant, cold water softeners are used to treat boiler water makeup. What’s less common is the use of a condensate polisher which treats condensate return for resuse as boiler feedwater. There are several differences between a water softener and a condensate polisher. Let’s look at a few:

Water Softener vs. Condensate Polisher
Installion – a water softener is typically installed “upfront” with the boiler system in order to meet the ASME/manufacturer’s water quality specifications. A condensate polisher is often an “add-on” to an existing boiler system once steam traps, condensate piping, and condensate receivers age and form deposits (such as iron, copper, and magnesium) that cause thermal resistance to drop.

Materials of construction – water softeners are constructed of epoxy coated tanks or poly-lined FRP tanks, with cast iron or PVC valves and black iron or PVC piping. Res-Kem’s standard condensate polisher systems are fabricated completely with stainless steel. This all stainless steel construction is the best material choice for safe operation over a long time.

Temperature & flow rate – condensate polishers are built to operate at a much higher temperature and flow rate. Where water softeners operate below 80 degrees F, polishers operate substantially above 120 degrees F. The higher temperature and flow rate allow a polisher to acts as both an ion exchange device AND filter, removing copper and iron oxides that cause scale buildup. This oxide removal is not possible with a water softener system, which act only as an ion exchange device with limited filtering capabilities.

Stainless steel surface preparation – condensate polishers are passivated. After fabrication, to further enhance the corrosion resistance of our stainless steel components, all of our welded stainless steel piping and tanks are passivated. This is an expensive, multi-step process which includes bead blasting and passivation, for the longest condensate polisher life.

So what do all these differences ultimately mean for a customer who invests in a condensate polisher?

1) Fuel savings – a condensate polisher saves fuel by allowing higher boilerwater cycles of concentration by reducing the Fe and Cu oxides that cause scale buildup. Fuel savings is also realized through the reuse of heat in the steam condensate.

2) Reduced chemical usage – because of the reduction of oxides and scale buildup in the steam loop, less investment is needed in internal boiler treatment chemicals that are used to remove buildup.

3) Longer and safer service life – a condensate polisher’s passivated, stainless steel construction ensures optimal operation for many years, with minimal routine maintenance. The typical life expectancy of a condensate polisher is 10-20 years.

Learn more about the customizable standard features and specifications of eight of Res-Kem’s recently manufactured condensate polisher models. Download our brochure today, then give us a call to see how we can help you “get greener” with more energy efficiency and more money in your pocket.

Q&A on Condensate Polishers with Res-Kem’s Kevin Preising

While dirty condensate clean-up can be an energy buster in most processing plants, one cost effective solution is to polish contaminated condensate for re-use. Condensate polishers use a simple ion exchange technology that is easy to operate, easy to maintain and economical to use – less make-up water is required which leads to lower chemical and energy consumption.

Here is a brief Q&A video with Res-Kem’s Process Engineer Kevin Preising that addresses some of the most common questions about Condensate Polishers. Kevin touches on the following points:
• The difference between sodium condensate polishers and water softeners
• The life expectancy of a condensate polisher
• What plant utility services are required for condensate polishers
• Why a sub-surface wash is important
• The advantage of using a sample cooler
• The type of instruments on a condensate polisher

Watch it now!

GlobalSpec Condensate Polisher Presentation Archive

GlobalSpec now has easier access to presentation archives from their Virtual tradeshows. Here is the presentation Kevin Preising gave at the "Industrial Processing" event in August of 2010 entitled "Reuse the energy - don't lose it!"

Why should I view the presentation?
With fuel comprising 60-70% of the operating costs of a typical steam plant, dumping high BTU steam condensate down the drain costs you money. Treating and reusing condensate with a condensate polishing system pays for itself in 12-18 months. This presentation will detail the economics of sodium cycle condensate polishers.

FYI, you may have to register with Globalspec, but it is easy and free to do so.

Condensate Polisher ROI Presentation

Reuse It – Don’t Lose It! The Economics of Condensate Polishing was presented at the GlobalSpec Industrial Processing virtual tradeshow on August 25, 2010. It is a rather long presentation so we posted in two pieces on YouTube.

Abstract of Presentation:
In today's environment of economic pressure and high energy costs, engineers are constantly asked to do more with less. A condensate polisher helps meet this challenge. Condensate polishers:

• Save energy by reclaiming heat normally sent to drain
• Save water by reducing boiler blow down
• Reduce water treatment chemical usage

This presentation will use real world examples to show how condensate polishing reduces fuel consumption and minimizes water side fouling in medium- and low-pressure steam plants typical of the food, beverage, and chemical process industries.

Economics of Condensate Polishers - Part 1


Economics of Condensate Polishers - Part 2

Presentation on Condensate Polisher ROI

As I alerted in a previous post, Kevin Preising of Res-Kem gave a webcast entitled "Reuse It or Lose It - The Economics of Condensate Polishing". This excellent webcast was given at the GlobalSpec Industrial Processing virtual trade show on August 25 showing how a condensate polisher can pay for itself in 9.6 months! You sve energy and water treatment chemicals.

You can see this presentation any time, day or night through GlobalSpec.

If you are not currently a GlobalSpec subscriber, you will need to register. It is painless and IT'S FREE.

Economics of Condensate Polishing

On August 25, 2010, Res-Kem's Kevin Preising will make a presentation entitled "Reuse It – Don’t Lose It! The Economics of Condensate Polishing" as part of the Industrial Processing on line tradeshow presented by GlobalSpec.

Abstract of Presentation:
In today's environment of economic pressure and high energy costs, engineers are constantly asked to do more with less. A condensate polisher helps meet this challenge.

Condensate Polishers:

• Save energy by reclaiming heat normally sent to drain


• Save water by reducing boiler blow down


• Reduce water treatment chemical usage.
  
  This presentation will use real world examples to show how condensate polishing reduces fuel consumption and minimizes water side fouling in medium- and low-pressure steam plants typical of the food, beverage, and chemical process industries. A follow-up Q&A will address technical aspects of condensate polishing set-up, operation, and maintenance.
  
  Key Take-Aways:


• Understand how a condensate polisher and water softener compare


• Learn how to justify the expenditure of a condensate polisher to save energy, water, and chemicals


• Know where to add a condensate polisher to treat your steam condensate


• The ROI of a condensate polisher is less than 10 months!

Kevin's presentation will take place from 3:30 PM - 4:30 PM EDT (12:30 PM - 1:30 PM PDT)

Click here to register for the event.

Condensate Polisher Savings of 23% Realized Through Value Engineering

The white paper, "Condensate Polisher Savings of 23% Realized Through Value Engineering", shows how a value engineering team comprised of personnel from a well-known university, Res-Kem Corp, and a mechanical contractor yielded the best system for the money.

These savings substantially improved the return on investment. This was accomplished without making any compromises on the installation costs, reliability of operation, or desired operating efficiency of the powerhouse.

The Problems:
All the qualified bids exceeded the set aside level of funding. During the time lag between project approval and initiation of the bidding process, a number of variables arose which collectively now jeopardized the project in its entirety.

The cost of stainless steel, while recognized to be escalating, continued
to climb beyond all reasonable expectations.

The university’s internal cost of capital was adversely affected by a tightening of available funds within the credit market. Almost immediately, the university comptroller put the project on hold and demanded an even higher return on investment in order for the project to proceed.

The Solution:
In an attempt to move the project forward, it was decided the university utility manager would work directly with the condensate polisher manufacturer and the winning bid mechanical contractor to see how best to value engineer the product offering. The targeted goal of the value engineering team was to reduce the purchase price of the condensate polisher by a minimum of twenty percent. This together with some labor saving initiatives taken on by the mechanical contractor installing the system would hopefully rescue the project.

Value Engineering Study Items and Savings

Downsize Vessel Size -- 4% Savings

Retain stainless steel vessel -- 0%

Retain C-150 resin -- 0%

Modify external piping -- 13% Savings

Modify control valves -- 6% Savings

Total Value Engineering Savings -- 23%

As shown in the above summary, the benefits of joining together a team of
knowledgeable and experienced individuals can be readily apparent. This is particularly true when the individuals come to the task with complementary but differing skill sets combined with a shared sense of purpose.