Success stories
Steam Plant for Obtaining Lactose-Free Ingredients from Yeasts
Project description
Installation of an integrated solution to optimize steam generation and distribution to feed six reactors where the customer’s product is produced. The installation includes a 15kW electric steam generator, a pressure reduction system, an insulated steam line, flexible piping for connection to reactors and a condensate separator.
Original situation:
Challenges posed by the client:
The customer is a food company specialized in the production of yeast-based ingredients to add creaminess to lactose-free products.
It faced a technical challenge in its manufacturing process. It needed to optimize the generation and distribution of steam to feed six reactors in which the production of its innovative product is carried out.
In addition, it had a number of requirements that the project had to meet:
- A specific steam generation range: the generator had to be able to produce between 20 kg/h and 150ºC, adapting to variations in demand without compromising the efficiency and quality of the steam generated.
- Minimum possible pressure: one of the key objectives was to operate at the lowest possible pressure to ensure the safety of the system and the integrity of the reactors.
- Efficient steam distribution: the system had to allow uniform steam distribution to six different reactors but also the possibility of shutting off steam distribution to those not in use.
Proposed solution:
Customized steam solution developed by Giconmes.
Proposed solution:
- Electric Steam Generator NGV1715 (15kW): we opted for an electric steam generator made of AISI 316 stainless steel, capable of generating steam in a constant and reliable manner, meeting the required range of 20 kg/h at 150°C. In addition, its compact design and low maintenance make it ideal for the customer’s facilities.
- Pressure Reduction System: A pressure reduction system was incorporated to allow the company to adjust the steam pressure according to the operating needs of the reactors. This allows greater flexibility and ensures a stable and safe supply at all stages of the process.
- Isolated Steam Line: We connected the generator to a steam line approximately 12 meters long, designed to minimize heat losses and maintain energy efficiency. The steam line incorporated six ball valves to manually open or close the steam supply to the individual reactors depending on their use, maximizing control and reducing energy waste when a reactor is not in operation.
- Flexible Piping for Reactor Connection: From each manifold valve, a flexible steam pipe is installed to connect to the reactors. This ensures easy connection and disconnection, ideal for fast and efficient maintenance.
- Condensate Separator: Just upstream of the ball valves, we incorporate a condensate separator. This component automatically purges liquid water from the system before the steam is distributed to the reactors, ensuring a dry steam supply, which is essential to maintain the quality of the final product.
Technology used:
- NGV1715
- Pressure reduction system
- Calorifuged pipe (12m)
- Ball valves
- Condensate separator
CHALLENGES
We meet customer requirements
We adapt to the customer’s specific steam generation range without compromising the efficiency and quality of the steam generated.
We included a pressure reduction system so that the company could adjust the steam pressure according to its needs.
We enabled efficient steam distribution with six ball valves to manually open or close the steam supply to the individual reactors.
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FAQs
We understand that many questions arise. Here are some of the most common ones.
There are no pollutant emissions beyond those produced in the electricity production process, therefore, they can become neutral depending on the electricity mix.
Electric steam boilers are the present and the future.
Perfectly.
It is even recommended for maximum efficiency.
There is no problem in remote control as long as the current regulations are respected.
A steam generator is a pressurized equipment that, together with the piping network it affects, is subject to regulatory control and complementary technical instructions, according to Regulation published in Royal Decree 809/2021, of September 21.
Its maintenance is divided into a part of simple compliance by the owner:
- Know and apply the manufacturer’s instructions regarding use, safety measures, and maintenance.
- Not to put the installation into service or prevent the operation of pressure equipment if the requirements of the Regulation are not met.
- Having at least the following documentation for the pressure equipment while they are installed: Declaration of conformity, manufacturer’s instructions (if applicable), and, if necessary, installation certificate, along with other supporting documentation (such as installation project, record of the last periodic inspection, certifications of equipment repairs or modifications, and any other documentation required by the relevant technical instruction complementary to this regulation). For detailed contents, refer to Annex IV of the regulation. Making this documentation available to the competent authority of the autonomous community and the companies responsible for maintenance, repair, or periodic inspections.
- Use the pressure equipment within its intended operating limits as specified by the manufacturer and take it out of service if it no longer meets the necessary safety requirements.
- Perform maintenance on the installations, pressure equipment, safety accessories, and control devices in accordance with the operating conditions and manufacturer’s instructions, and examine them at least once a year.
- Arranging for the necessary periodic inspections as required by Article 6 of the regulation.
- Having and maintaining an up-to-date record of pressure equipment categories I to IV, as defined in RD 709/2015, of July 24, or equipment similar to these categories according to Article 3.2 of the regulation, as well as their installations.
It is known that by applying a heat source to water, it is transformed into steam from the boiling point and at atmospheric pressure.
From this point on, depending on the required degree of saturation of the steam for its correct application, we will have to increase the pressure in order to obtain a higher temperature.
To change the temperature and degree of saturation of the steam, we must always modify the pressure.
It is a unit of pressure equivalent to 1 kg/cm2, 0.98 atmospheres, or 14.50 PSI.
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