Process Int - Training

Energy-Efficient Steam Systems

Key Benefits

  • Understanding the design and operation of the major components of steam systems
  • Understanding steam systems in the process industries for increased efficiency
  • Optimization of site utility systems for reduced fuel and power costs
  • Energy saving and increased power production through better matching between process requirements and steam levels
  • Specifying steam costs for the distribution of costs between different businesses on a site
  • Specifying steam costs for energy reduction projects
  • Identification of steam system improvements


Almost half of the fuel consumed to meet industrial energy requirements is used in the production of steam. Most sites have scope to increase the efficiency of fuel conversion. Significant cost savings are thus possible on most sites.


Relatively simple measures such as control of boiler blowdown, maintenance of steam traps, the recovery of flash steam, and increasing condensate return rates, can make immediate and significant cost savings in the generation and use of steam. Optimisation of the system can often bring high returns with little investment.

This course examines the production of steam from fuel combustion and water supply, through to distribution and use. Models and tools are developed that can be easily applied in the design and operation of steam systems in order to minimise operation costs and, where appropriate, to maximise the effectiveness of capital expenditure.

In addition, these tools can be used to determine and assess new investment proposals or to provide long-term investment plans for the infrastructure to allow for projected changes in the patterns of production.

Who Should Be Trained?

The training is intended for people with a chemical or mechanical engineering background working in the process industries, or in engineering and consultancy companies servicing those industries. Process engineers, utility engineers and managers, and energy managers should attend this course.

Dates & Course Fees

The next available public training will take place on 14th September 2017.

We can also offer a two-day course to be delivered in-house at your business, please contact us to discuss this option. Note: To register your interest in this course and request a programme schedule, please contact This email address is being protected from spambots. You need JavaScript enabled to view it.


Session 1 Introduction

Background to the importance of steam systems and incentives for improvement

Session 2 Fuels, Combustion, and Emissions

Heating values of fuels, combustion calculations, excess air

Session 3 Boiler Feedwater Treatment

Chemical treatment, ion exchange, deaerator operation

Session 4 Boilers

Boiler types, economisers, air pre-heaters, burner design, boiler modelling

Session 5 Gas Turbines

Characteristics of gas turbines, performance, emissions, gas turbine modelling

Session 6 Gas Turbine Heat Recovery

Matching gas turbines with heat recovery steam generators, efficiency of heat recovery

Session 7 Steam Turbines

Steam turbine configuration, performance and modelling of steam turbines

Session 8 Steam Use

Steam heaters, reboilers, steam traps

Session 9 Steam Distribution

Steam systems, flash steam recovery, condensate return, piping and insulation

Session 10 Steam Balances and Energy Audits

Steam balance construction, operational variations, what-if scenarios

Session 11 Steam System Optimisation

Modelling steam systems, cost optimisation

Session 12 Retrofit

Retrofit objectives, retrofit design methods, automated retrofit methods

Session 13 Heat Engines, Heat Pumps and Refrigeration

Principles for the integration of heat engines, heat pumps and refrigeration

Session 14 Steam Pricing

Calculation methods, true cost of steam

Session 15 Site Composite Curves

Energy targets for the utility system. Heat recovery through the steam system

Session 16 Targeting and Design for Steam Turbine Systems

Predicting power generation from steam turbines for the site, network design

Session 17 Optimising Steam Levels

Optimising steam levels for minimum energy and minimum cost

Session 18 Site Power to Heat Ratio

Choice of cogeneration system for different site power to heat ratios

Session 19 Driver Selection

Appropriate use of electric motors, steam turbines, turbo expanders, gas turbines, gas engines, diesel engines

Session 20 Optimisation of Driver Selection

Use of optimisation for the automatic selection of drivers

Session 21 Conclusions

Major issues in steam system design

Learn More from Process Integration

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