Modernization of steam heat exchangers

Steam heat exchangers are a key source of heat in industrial processes. Thanks to the modernization of 17 units, DB Energy’s client reduced energy losses, improved heat exchange efficiency, and achieved annual savings of over PLN 10 million with a payback period of less than 2 years.

The challenge

At one of DB Energy’s clients, the main source of heat in the production process was steam heat exchangers connected to the plant’s heating system. The audited facility had 17 exchangers with a nominal capacity of approx. 2 MW each.

The exchangers were aging, and their external surfaces reached very high temperatures. This indicated significant heat losses to the environment – approx. 100 kW per unit. Additionally, internal piping accumulated deposits from the heated electrolyte, leading to leaks and frequent maintenance requirements.

Our approach

The DB Energy team conducted a detailed analysis of the exchangers' operation:

flow and temperature measurements on supply and return pipes,
condensate temperature measurement and calculation of the indirect steam power flow,
development of a heat balance for all 17 exchangers,
assessment of the efficiency of existing exchangers and identification of energy losses.

Based on this, we prepared modernization recommendations considering both technical parameters and investment profitability.

Solution

It was proposed to replace all exchangers with new units with heat exchange efficiency rated at 82–90%. For profitability analysis, a conservative efficiency of 65% was assumed, accounting for possible system losses.

Modernization included:

replacement of all 17 exchangers,
integration of the new units with the existing plant heating system,
minimization of downtime through a work schedule adapted to production processes.

Results

The implementation brought tangible benefits in the form of:

reduction of average annual energy consumption by 80,008 MWh,
financial savings of approximately PLN 10.12 million per year,
simple payback period: under 2 years,
higher energy efficiency and operational stability of the exchangers,
reduction of heat losses to the environment and lower maintenance costs.

Total modernization cost did not exceed PLN 5.3 million.

Conclusions

The modernization of steam heat exchangers shows that investments in replacing key process equipment deliver significant energy and cost savings. A precise audit and detailed heat balance analysis enable the selection of an optimal technical solution, which quickly pays off through reduced energy expenses and increased process reliability.

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