Steam System Performance Programme
Save boiler fuel, water and treatment chemicals using our proven, structured approach to steam system optimisation.
A steam system encompasses steam generation (boiler plant), steam distribution, users of steam and the recovery of condensate. Steam systems are typically one of the more costly utility systems to operate and are responsible for a large chunk of energy use and Scope 1 emissions at a typical factory.
The largest optimisation opportunities come from addressing the system as a whole instead of focusing on individual elements of the system. VWG’s Steam System Performance Programme identifies opportunities across the steam system, develops these into bankable projects, implements these projects and then monitors them to ensure that each individual project continues to deliver expected results. In addition, the programme conducts routine monitoring of the steam system to ensure its basic operation is efficient. This is done through local measurements taken during site visits and, where sites make the investment in online metering systems, remotely.
The programme is offered through 2 formats:
1. Fixed monthly fee option
In this format, a fee is paid for the service and the costs of project implementation are borne by the participating site. Fees range from R10,000 – R40,000/month excluding travel, and depend on the operating costs of the steam system.
2. Shared value option
With this option there are no upfront fees. All costs for the programme, except for travel, are paid for from the savings generated. These savings are shared between VWG and the participating site for a limited period for each project, after which the project matures. Mature projects are them monitored for a small fee, with the site retaining the bulk of the savings. Where projects require funding, the site has first option to fund them. If the site prefers that VWG funds a project, then the project savings will first be used to refund the project costs plus a risk premium before value is shared by the parties. Assets will in all cases be the property of the participating site. This options gives sites a range of benefits:
- Access to resource efficiency engineering expertise at no cost
- Sites only pay if they save
- Sites gain assets without having to invest capital
- No costs for routine monthly reporting and measurements
What kinds of projects are implemented?
The programme takes every opportunity to enhance steam system efficiency. Project types include:
- No-cost projects that involve changes to settings or work practices e.g. adjustments to air-to-fuel ratios to enhance boiler efficiency
- Low-cost projects that encompass minor modifications e.g. changes to hotwell level control systems
- Medium-cost projects involving moderate modifications e.g. insulation projects or installation of condensate recovery lines
- Investment projects that significantly modify the steam system e.g. installation of a feedwater economiser, vent condenser or flash tank
Every project is carefully developed through rigorous measurement and modelling, giving a clear indication of expected savings prior to implementation. Projects are monitored after implementation to sustain their performance, and verified resource savings, cost savings and emission reductions are determined and reported on each month.