A pharmaceutical plant in North-West India, using sustenance service for CRF

A pharmaceutical plant in North India producing tablets, capsules, liquids, and powders faced significant inefficiencies in its steam and condensate system. The key steam-consuming equipment includes Pure Steam Generation (PSG), distillation columns, and water for injection (WFI) tanks. Our condensate recovery system, installed in 2020 had a significant impact on the Condensate recovery factor (CRF) and operational cost, however, operations over time resulted in a fall in CRF due to various issues. In 2023 CRF was approximately 60% (below industry benchmark) while the feedwater temperature was between 55-60°C.

We started the digital sustenance service for CRF in 2024. Once the real-time data started streaming from key areas of the plant impacting CRF, our engineers identified different issues related to condensate and flash steam through the data. Major amounts of flash steam from the medium pressure steam of PSG was not recovered to the feed water tank. Process & mainline trap uptime was observed to be around 70%, which should be >95%. The feed water tank hook-up was incorrect due to which condensate & flash is not quenching properly. Maintaining the higher level in the feed tank caused lower feed water temperature.

Objective

PROBLEM

– Condensate recovery factor (CRF) was low, at approx. 60%

– Inefficient flash steam recovery to the feedwater tank

– Back pressure issues due to incorrect condensate line hook-up

– Higher boiler feed water tank level maintained, causing lower feed temperature.

– Trap uptime at 70% instead of the expected >95%

Problem

OBJECTIVE

– To improve the efficiency of the steam and condensate recovery system, increasing condensate recovery factor, optimising feedwater temperature, eliminating backpressure, and improving trap uptime. Ensuring safe and smooth condensate system operation.

Solution

SOLUTION

– Recovered flash steam from the medium pressure condensate and directed it back to feedwater tank

– Connected a condensate pump in-line from one section to recover more condensate

– Modified the condensate network to separate and low pressure condensate streams

– Optimised the feedwater tank temperature level by controlling the make-up water.

– Repaired or replaced faulty traps, ensuring better performance and efficiency

Benefit

BENEFITS

– Increased CRF from 60% to 85%

– Improved feed water tank temperature from 68°C to 89°C

– Reduced make-up water usage due to increased condensate return

– 3.5% boiler fuel consumption savings due to correct feed water temperature

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