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A healthcare company has achieved a 12-month payback on Thermal Energy’s GEM venturi orifice steam traps installed at its manufacturing facility in Italy.

The facility’s process plant had been experiencing problems of mechanical steam trap failure and high maintenance costs. As a result, Thermal Energy was asked to conduct a survey of the site’s steam traps, which were regularly failing open, partly open and closed, leading to both scheduled and unscheduled maintenance.

Thermal Energy carried out a metered test on a process application and then conducted a positive bucket test. Of the 51 steam traps surveyed, 30 per cent had failed, resulting in an estimated 757 tonnes per year of steam being lost at a cost of about €31,000 (£24,000).

A total of 92 steam traps from Thermal Energy have now been installed throughout the facility’s process plant, removing the problems of mechanical steam trap failure and high maintenance costs.

Key benefits of product application

  • As a result of the project, the healthcare company is saving energy and maintenance costs and is expected to reduce its start-up times and its carbon dioxide emissions by 131 tonnes.
  • Thermal Energy demonstrated that, by replacing the existing traps with the GEM venturi orifice design, blocked steam traps could be prevented from negatively affecting production and start-up times; in addition, by efficiently returning condensate back to the boilers, energy savings could be achieved.
  • Instead of utilising a valve mechanism to close off steam for maximum energy and water conservation, the GEM steam traps use the venturi orifice design to effectively drain condensate from the steam system.
  • As the GEM steam traps have no moving parts to wedge open or fail, they offer excellent reliability, necessitating only minimal maintenance and requiring no spares, testing or monitoring equipment.
  • The hardwearing GEM steam traps are manufactured from corrosion-resistant stainless steel and are guaranteed for 10 years, removing the need for repair or replacement.
  • The GEM steam traps improve product processing by enhancing the quality of steam; they also reduce equipment repairs, downtime and replacement costs.
  • The healthcare company said it plans to install further GEM traps as more improvements and investments are made at the facility.

Thermal Energy International Inc is an innovative technology company providing custom energy and emission reduction solutions. Our award-winning energy recovery, conservation and bioenergy solutions provide significant financial and environmental benefits to our customers. Our experience and talent in waste energy recovery recycling and bio-energy conversion solutions are unrivalled. These solutions provide our clients with typical energy cost savings of 10 per cent to 35 per cent or more with commensurate reductions in greenhouse gases and other emissions.

We go beyond the realm of single application or product competitors and instead provide our clients with maximum opportunities to reduce energy and emissions. Through a unique mix of process, energy, environmental, financial and other expertise combined with the best technology solutions and financial offerings, our clients can expect compelling returns exceeding 30 per cent and solutions with an excellent track record of longevity, proven reliability and performance.

Thermal Energy's core business provides three primary client benefits:

  • Energy consumption and cost reduction
  • Commensurate greenhouse gas and emission reductions
  • Excellent financial returns

With energy cost trends projecting steady increases over the next several years, our solutions provide increasingly more attractive returns and a means for our clients to shield themselves against ever-increasing energy costs.

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