Steam
Over 45% of all the fuel burned by U.S. manufacturers is consumed to raise steam. Steam is used to heat raw materials and treat semi-finished products. It is also a power source for equipment, as well as for building heat and electricity generation. Many manufacturing facilities can recapture energy through the installation of more efficient steam equipment and processes. The whole system must be considered to optimize energy and cost savings. Such as: (Download Adobe Reader)
- Steam Generation through cogeneration applications, boiler controls, and water treatment
- Steam Distribution through checking steam leaks, installing insulation and proper steam trap maintenance
- Steam End Use through heat exchanger maintenance
- Steam Recovery through condensate return
Steam Case Studies
- J.R. Simplot: Burner Upgrade Project Improves Performance and Saves Energy at a Large Food Processing Plant (PDF 638 KB)
Steam Tip Sheets
- Click here for a complete list of steam system tip sheets.
Technical Publications
- Achieve Steam System Excellence: Industrial Technologies Program BestPractices Steam Overview (PDF 279 KB)
- Steam System Opportunity Assessment for the Pulp and Paper, Chemical Manufacturing, and Petroleum Refining Industries
- Main Report: (PDF 1.3 MB)
- Appendices: (PDF 2.4 MB)
- Steam Digest: Volume IV (2003): A compendium of articles published on steam system management and resources
- Steam Digest 2002: A compendium of articles published on steam system management and resources
- Steam Digest 2001: A compendium of articles published on steam system management and resources
- Guide to Combined Heat and Power Systems for Boiler Owners and Operators (PDF 3 MB)
- Guide to Low-Emission Boiler and Combustion Equipment Selection (PDF 2 MB)
- Steam System Survey Guide (PDF 708 KB)
- Review of Orifice Plate Steam Traps (PDF 1.1 MB)
- Steam Software Tools (PDF 734 KB)
Training
Learn more about ITP's Steam Systems Assessment training options.
Steam System Tool Suite
If you consider potential steam system improvements in your plant, the results could be worthwhile. In fact, in many facilities, steam system improvements can save 10% to 20% in fuel costs.
To help you tap into potential savings in your facility, DOE offers a suite of tools for evaluating and identifying steam system improvements. Learn more about the tools and specialized training, and download software here.
- Fact Sheet (PDF 129 KB) Download Adobe Reader
- Steam System Scoping Tool
This tool is designed to help steam system energy managers and operations personnel to perform initial self-assessments of their steam systems. This tool will profile and grade steam system operations and management. This tool will help you to evaluate your steam system operations against best practices.
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- Steam System Assessment Tool (SSAT) Version 2.0.0 The Steam System Assessment Tool (SSAT) allows steam analysts to develop approximate models of real steam systems. Using these models, you can apply SSAT to quantify the magnitude—energy, cost, and emissions-savings—of key potential steam improvement opportunities. SSAT contains the key features of typical steam systems.
The enhanced and improved version includes features such as a steam demand savings project; a user-defined fuel model; a boiler stack loss worksheet for the SSAT fuels; a boiler flash steam recovery model; and improved steam trap models.
Note: If you have SSAT Version 1.0.0 installed, it is recommended that you perform a complete update to the new version. Installing SSAT Version 2.0.0 will not erase any software templates you have previously created. Or, you can continue to use Version 1.0.0, but load the new software template files and save them in your existing SSAT "Templates" folder.
Update January 7, 2005: An error was discovered in the 2-header template included in the full version of the SSAT Version 2.0.0 download file. However, the corrected 2-header template is provided below. First install the full SSAT Version 2.0.0 software, then download the corrected 2-header template ("ssat2_header_v2-11.xls"), and put this template in the SSAT "Templates" folder on your computer.
Update May 21, 2007:SSAT will not operate with Microsoft's Windows Vista operating system and Excel when used with Office 2007. The tool will continue to operate successfully on older versions of Microsoft Windows and Excel programs. An update is in development and will be available for download on this Web site.
Download Software (Full Version - Includes all Header Models) - 3E Plus Version 3.2
The program calculates the most economical thickness of industrial insulation for user input operating conditions. You can make calculations using the built-in thermal performance relationships of generic insulation materials or supply conductivity data for other materials.
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You can get help on software installation and operation from the EERE Information Center at 1-877-EERE-INF (877-337-3463) or email to [email protected].