{"id":26118,"date":"2021-07-12T09:00:36","date_gmt":"2021-07-12T09:00:36","guid":{"rendered":"https:\/\/tecnologiaparalaindustria.com\/?p=26118"},"modified":"2025-07-22T12:16:56","modified_gmt":"2025-07-22T12:16:56","slug":"consejos-para-optimizar-los-sistemas-de-retorno-de-condensado-en-la-caldera","status":"publish","type":"post","link":"https:\/\/tecnologiaparalaindustria.com\/en\/consejos-para-optimizar-los-sistemas-de-retorno-de-condensado-en-la-caldera\/","title":{"rendered":"Tips for optimising condensate return systems in boilers"},"content":{"rendered":"<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_82_2 counter-hierarchy ez-toc-counter ez-toc-grey ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">Table of Contents<\/p>\n<span class=\"ez-toc-title-toggle\"><a href=\"#\" class=\"ez-toc-pull-right ez-toc-btn ez-toc-btn-xs ez-toc-btn-default ez-toc-toggle\" aria-label=\"Toggle Table of Contents\"><span class=\"ez-toc-js-icon-con\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #999;color:#999\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewbox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #999;color:#999\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewbox=\"0 0 24 24\" version=\"1.2\" baseprofile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/span><\/a><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1' ><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/tecnologiaparalaindustria.com\/en\/consejos-para-optimizar-los-sistemas-de-retorno-de-condensado-en-la-caldera\/#Como_se_pueden_mejorar_los_sistemas_de_retorno_de_condensado\" >How condensate return systems can be improved<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/tecnologiaparalaindustria.com\/en\/consejos-para-optimizar-los-sistemas-de-retorno-de-condensado-en-la-caldera\/#Ejemplo_de_garantia_de_sistemas_de_retorno_de_condensado_en_la_caldera\" >Example of guarantee of condensate return systems in boilers<\/a><\/li><\/ul><\/nav><\/div>\n<p class=\"p1\">Condensate return systems are an often overlooked part of a boiler system that allows you to recover valuable BTUs within your system. The sole purpose of a condensate return system is to collect condensate from different points in the system and return it to the boiler to save energy.<\/p>\n<p class=\"p1\">But why worry about condensate return in steam installations? The use of a condensate return system in conjunction with boiler and boiler feedwater preparation improves efficiency and reduces costs in the following ways:<\/p>\n<ul class=\"ul1\">\n<li class=\"li1\">The condensate has passed through the chemical treatment process in the boiler. Returning the condensate to the boiler or feed water reduces the total dissolved solids (TDS) in the system. It may result in less chemical treatment and may reduce the blowdown loss.<\/li>\n<li class=\"li1\">When the condensate returns to the boiler or feed water system, its temperature varies from 54\u00baC to 104\u00baC depending on the duration of the return system and other factors. This return temperature is much higher than the average temperature of the feed water and make-up water (10\u00baC to 16\u00baC). As a condensate return system it can significantly reduce the amount of money needed to produce steam.<\/li>\n<li class=\"li1\">Another benefit of a condensate return system is that it can reduce the amount of make-up water needed in your boiler. Helping to reduce your water consumption and improve savings.<\/li>\n<\/ul>\n<h3 class=\"p3\"><span class=\"ez-toc-section\" id=\"Como_se_pueden_mejorar_los_sistemas_de_retorno_de_condensado\"><\/span><b>How condensate return systems can be improved<\/b><span class=\"ez-toc-section-end\"><\/span><\/h3>\n<ul class=\"ul1\">\n<li class=\"li1\"><b>Vapour trap surveys<\/b>\n<p class=\"p1\">The <a href=\"https:\/\/tecnologiaparalaindustria.com\/en\/pasos-para-optimizar-la-operacion-de-las-trampas-de-vapor\/\" target=\"_blank\" rel=\"noopener\"><span class=\"s1\"><b>Condensate is discharged from the equipment through steam traps.<\/b><\/span><\/a>. A steam trap simply allows condensate (condensed steam also known as water) to pass through while retaining (or trapping) the steam. This ensures that steam that has not yet given up its energy remains in the system while the condensate is removed.<\/p>\n<p class=\"p1\">As you can imagine, a malfunctioning or incorrectly sized steam trap can wreak havoc on your condensate return system. A steam trap that has gone bad can be left open or closed. As one of the few moving parts in your steam system, it is important to <a href=\"https:\/\/tecnologiaparalaindustria.com\/en\/conoce-el-coste-total-de-los-problemas-en-trampas-de-vapor-con-un-ejemplo-en-plantas-de-procesos\/\" target=\"_blank\" rel=\"noopener\"><span class=\"s1\"><b>perform regular inspections of steam traps<\/b><\/span><\/a>.<\/p>\n<p class=\"p1\">By ensuring that the <a href=\"https:\/\/tecnologiaparalaindustria.com\/en\/impacto-de-los-fallos-en-trampas-de-vapor-en-plantas-de-procesos\/\" target=\"_blank\" rel=\"noopener\"><span class=\"s1\"><b>steam traps<\/b><\/span><\/a> are properly sized and function properly, you can keep your condensate return system running efficiently. A faulty steam trap can cause water hammer (noisy noises). The <a href=\"https:\/\/vaporparalaindustria.com\/9-formas-para-evitar-los-problemas-de-golpe-de-ariete-en-tuberias-de-vapor\/\" target=\"_blank\" rel=\"noopener\"><span class=\"s1\"><b>water hammer<\/b><\/span><\/a> excessive will result in breakage of additional piping, hangers, valves and pipe fittings. Note: High pressure traps should be tested quarterly.<\/p>\n<\/li>\n<\/ul>\n<ul class=\"ul1\">\n<li class=\"li1\"><b>Capture flash steam<\/b>\n<p class=\"p1\">After the condensate passes through a steam trap, a pressure change occurs. This causes some of the condensate to become flash steam. This is another area where many companies may be losing money. If this flash steam is vented to the atmosphere, you are losing the valuable BTUs it contains. Instead, collect the steam in a flash vessel and use it to heat somewhere in the system. Also be sure to recover any condensate created when the revaporate gives up its energy and use that as well.<\/p>\n<\/li>\n<\/ul>\n<ul class=\"ul1\">\n<li class=\"li1\"><b>Detect leaks and corrosion<\/b>\n<p class=\"p1\">The condensate pipe has to deal with a higher concentration of carbonic acid than the rest of the system. This is because CO2 dissolves more easily in the cooling condensate. This can lead to corrosion of the steel which can eventually lead to leaks. Check your system for leaks and repair any that are found immediately to ensure that savings do not escape from your pipes.<\/p>\n<\/li>\n<\/ul>\n<ul class=\"ul1\">\n<li class=\"li1\"><b>Insulate the pipe<\/b>\n<p class=\"p1\">Insulation can normally reduce energy losses in a 90% and help ensure adequate steam pressure in plant equipment. Any surface above 48\u00b0C should be insulated, including boiler surfaces, steam and condensate return piping and fittings.<\/p>\n<p class=\"p1\">The better you can help condensate retain its heat, the more efficient your system will be. That's why insulation is a no-brainer. It allows condensate to hold its heat longer, resulting in less work for the boiler and ultimately saving you money.<\/p>\n<p class=\"alert alert-warning\">Check your entire system and make sure all pipes are insulated. Repair uninsulated areas to ensure that you do not lose large amounts of heat as condensate returns.<\/p>\n<\/li>\n<\/ul>\n<ul class=\"ul1\">\n<li class=\"li1\"><b>Return of contaminated condensate<\/b>\n<p class=\"p1\">In some cases, there may be a risk of contamination if condensate returns to the boiler. If it is contaminated with corrosive liquids, for example, it is not suitable for boiler feed water. This is due to the dangers of foaming, scaling and corrosion.<\/p>\n<p class=\"p1\">Condensate contamination detection equipment can detect changes in the conductivity of condensate. When a change in the desired conductivity occurs, sensors recognise that the condensate is contaminated. A controller then signals a discharge valve to open. This allows the condensate to flow to the drain or an economiser, rather than back to the boiler.<\/p>\n<\/li>\n<\/ul>\n<h3><\/h3>\n<h3 class=\"p3\"><span class=\"ez-toc-section\" id=\"Ejemplo_de_garantia_de_sistemas_de_retorno_de_condensado_en_la_caldera\"><\/span><b>Example of guarantee of condensate return systems in boilers<\/b><span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p class=\"p1\">Consider a steam system that returns an additional 10,000 euros per hour (e\/h) of condensate at 82\u00b0C after distribution modifications. Assume this system operates 8,000 hours per year with an average boiler efficiency of 80% and a make-up water temperature of 13\u00b0C. The plant's water and sewer costs are \u20ac0.002 per gallon (\u20ac\/gal) and the cost of water treatment is \u20ac0.002\/gal. The fuel cost is \u20ac 8.00 per million Btu (\u20ac 8.00 \/ MMBtu). Assuming a flash steam loss of 12%, * calculate the total savings.<\/p>\n<p class=\"p1\">If you are interested in optimising condensate return systems in the boiler, we invite you to find out which are the most efficient and efficient condensate return systems in the boiler. <a href=\"https:\/\/tecnologiaparalaindustria.com\/en\/cuales-son-los-criterios-para-elegir-un-proveedor-de-maquinaria-para-la-manufactura-electronica\/\" target=\"_blank\" rel=\"noopener\"><span class=\"s1\"><b>criteria for choosing an electronics manufacturing machinery supplier<\/b><\/span><\/a>as well as <a href=\"https:\/\/koi-3QNFFA4OII.marketingautomation.services\/net\/m?md=1hu2UUuQ0QrwApavxq%2BKeXOntDiuzdVO\" target=\"_blank\" rel=\"noopener\"><span class=\"s1\"><b>subscribe to our newsletter<\/b><\/span><\/a>a monthly newsletter with technical content that will help you to obtain useful and up-to-date information on plant efficiency and operating performance in steam plants.<\/p>","protected":false},"excerpt":{"rendered":"<p>Los sistemas de retorno de condensado son una parte que a menudo se pasa por alto de un sistema de caldera que le permite recuperar BTU valiosas dentro de su &hellip;<\/p>","protected":false},"author":2,"featured_media":26119,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_genesis_hide_title":false,"_genesis_hide_breadcrumbs":false,"_genesis_hide_singular_image":false,"_genesis_hide_footer_widgets":false,"_genesis_custom_body_class":"","_genesis_custom_post_class":"","_genesis_layout":"","footnotes":""},"categories":[496],"tags":[],"class_list":["type-post","category-equipos-industriales","CTA-cta-general","CTA-spirax-sarco","cliente-spirax-sarco","entry"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Optimizar los sistemas de retorno de condensado en la 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