Proven steam and energy savings in real plants
Results from chemical, paper and tissue, corrugated packaging, textile, food, tyre, power and wood-drying plants and building services — thermocompressors, controlled steam ejectors, jet pumps and steam stations at work.
- 10–25%
- Typical steam / fuel saving
- 6–18 months
- Typical payback
- 11
- Industries
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Chemical 45 lakh a year Vent flash steam recovered into process steam
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Corrugated packaging ~15% less fuel, held over seven months Corrugator steam system retrofit
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Paper 32% less steam on a Yankee dryer Yankee dryer: blow-through steam recirculated
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Textile +100% fabric speed on the same steam Drying tower: eight cylinders on one recirculation loop
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Paper 2.6 to 2.2 t steam per ton of paper Paper machine dryer drums on controlled ejectors
- Paper 3–5% more throughput per filling
Wood-chip stoves filled at higher steam pressure
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Corrugated packaging 25% less energy per tonne of board Corrugators on a closed steam and condensate cycle
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Textile 2 to 3 barg vent steam reused (design example) Vented low-pressure steam recompressed for reuse
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Corrugated packaging 32% steam saved, customer-reported Corrugator dryers on controlled ejectors
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Chemical 18 lakh a year saved on seven air heaters Coating-line air heaters: coil flash steam recirculated
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Other 230 MWh saved in the first four months Industrial laundry: process flash steam lifted to 4 bar g
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Textile 15% steam saved Textile washing and drying on controlled ejectors
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Tyre & Rubber 23% less steam at a tyre plant Curing presses and ovens on one recirculation main
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Textile 20% steam saved Textile drum dryers on controlled ejectors
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Chemical 3.8 crore a year from flash steam that used to vent Condensate-drum flash steam lifted into the LP header
- Textile 15% primary energy saved
A new steam and power concept for a textile plant
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Corrugated packaging 10–20% steam / fuel saving expected Corrugator control with valves and controllers
- Food & beverage 10.6 lakh a year from a closed condensate tank
Open condensate tank closed, its steam to the deaerator
- Plywood 27.6% less fuel per m³ of board
Board dryer and press on recirculation loops
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Food & beverage 1,240 kg/h steam recovered Faulty steam ejector resized, venting stopped
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Tyre & Rubber 40–50% less steam on a rubber press Vulcanising press on one recirculation loop
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Building services Buildings Hot-water heating with jet-pump mixing
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Paper 1.66 to 1.56 t steam per tonne of paper Paper machine cascade made a direct steam system
- Tyre & Rubber 15 t a day press exhaust steam reused
Curing-press exhaust steam reused for low-pressure users
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Timber & wood drying 60 lakh a year electricity saving Wood-drying ovens on hot-water jet pumps
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Food & beverage +18% disc dryer output, one extra batch a day Disc dryer on steam recirculation
- Chemical 28.3% less fuel per tonne of sludge
Sludge dryer: traps out, tank flash recirculated
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Paper since 1998 a Jetomat on a tissue machine’s Yankee Tissue machine Yankee on a variable-nozzle Jetomat
- Textile 15% less steam per unit of fabric
Fabric drum dryer on two recirculating Jetomats
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Power generation 260 kg/h flash steam recovered Condensate-vessel flash steam to the water heaters
- Corrugated packaging 24.6% less fuel oil at a corrugator
Corrugator dryers and presses on flash recirculation
- Chemical 3 reactors on steam recirculation since 2000
High-pressure reactor heating on steam recirculation
- Chemical 59 lakh a year of steam loss found at 33 leaking traps
Steam trap audit on a running plant
More case studies for this industry are on the way — ask us for a reference.
Some of the plants we work with
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