Impact of a High-Pressure Condensate Return System Upgrade on Boiler Fuel and Utility Consumption: A Case Study in a Corrugated Board Manufacturing Plant
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This study evaluates the technical and economic performance of a high-pressure condensate return system installed on an 8-ton industrial steam boiler at a corrugated board manufacturing plant in Samut Sakhon, Thailand. Before installation, surface temperatures at ten steam-trap points ranged from 129◦C to 166◦C, while the feedwater holding tank temperature was 50–60◦C. A 15-kW high-pressure booster pump and 300-liter tank were installed to improve condensate recovery. Following installation, annual heavy fuel oil (HFO) consumption decreased by 58.5%, from 1,202,000 liters in 2022 to 498,500 liters in 2023, with comparable production output. Annual water consumption decreased by 28.9% (5,896,000 liters), and electricity consumption decreased by 10.3%. The feedwater holding tank temperature increased to approximately 150◦C. Net annual monetary savings, after additional pump electricity costs, reached 21,197,558 THB. Over five years at a 6.25% discount rate, the project achieved an NPV of 86,187,810 THB, IRR of approximately 848%, and simple payback of approximately 43 days. However, fuel savings reflect both the pump upgrade and concurrent steam-trap repairs. High-pressure condensate recovery can improve resource efficiency, but site-specific assessment and further validation are recommended.
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