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MAXIFLO® EJECTOR SYSTEM

AN INNOVATIVE APPROACH

TO STEAM CONSERVATION

LEVEL 4 BEEACCREDITED

INTRODUCTION

The Maxiflo is a highly efficient condensate

removal system which is an alternative to

conventional steam traps.

Unlike steam traps, the Maxiflo has as no

moving parts and harnesses kinetic energy

from steam, to eject condensate continuously.

The rapid ejection process improves thermal

efficiency of process equipment by up to 20%.

CONDENSATE

REMOVAL SYSTEMS

PART 1

Condensate removal with

steam traps.

PART 2

Condensate removal with the

Maxiflo® ejector system.

CONDENSATE REMOVAL WITH

STEAM TRAPS

Steam traps are automatic valves which

cycle open to discharge condensate from

equipment and close to retain the live

steam.

COMMON TYPES OF

STEAM TRAPS

• Inverted Bucket Trap

• Float & Thermostatic Trap

• Thermodynamic Trap

• Thermostatic Trap

INVERTED BUCKET

FLOAT & THERMOSTATIC

THERMODYNAMIC TRAP

THERMOSTATIC TRAP

DISADVANTAGES OF

STEAM TRAPS

• They require regular testing &

maintenance to operate efficiently.

• Different types of traps require different

test equipment and procedures.

TYPICAL MAINTENANCE

PROGRAM

• According to the manufacturers, steam

traps should be tested 2 to 3 times a year.

• Faulty traps must be repaired or replaced,

immediately after detection.

THERMAL IMAGES OF STEAM

TRAPS ON SIMILAR APPLICATIONS

Failed open Working order

ACTUAL FAILED TRAPS

• Trap internals eroded from steam blow.

• Ball floats damaged from waterhammer.

THE RESULT OF TRAP FAILURE

• Because the default failure mode of

steam traps is in the open position,

just one failed open trap at 10 bar can

cost R 63 000 per year in steam loss.

CONDENSATE REMOVAL WITH THE

MAXIFLO EJECTOR SYSTEM

The Maxiflo® ejector is an alternative

system which uses kinetic energy from

steam, to discharge condensate from

equipment, while retaining the live steam.

MAXIFLO® RANGE

• 15, 20, 25, 40 & 50 mm Nominal Bore

• Screwed, Flanged, Socket weld or Wafer

MAXIFLO® SYSTEM

• Has no moving parts.

• Stainless steel construction.

THE DIFFERENCE BETWEEN

MAXIFLO® AND STEAM TRAPS

• Steam traps have moving parts and

discharge condensate in cycles.

• Maxiflo ejectors are static and use

kinetic energy from steam to eject

condensate continuously.

Principle of operation to follow…

THE DENSITY OF STEAM

COMPARED TO CONDENSATE

• The turbulent condensate discharge through the

ejector effectively “blocks” the steam passage.

As steam and condensate travel towards

the Maxiflo ejector : -

• Both try to pass through the

ejector at the same time.

• The higher density condensate

is always forced through first,

by the steam pressure.

THEORY CONFIRMED BY THERMAL

IMAGE OF MAXIFLO®

The continuous discharge of condensate (maroon)

holds the steam (yellow) back in the line.

EXAMPLE OF MAXIFLO® ON A

CORRUGATING ROLL

The Maxiflo can discharge a large mass

of condensate, but only a small mass

of steam.

The reason being that condensate has a

greater density than steam.

animation to follow…

MAXIFLO® DISCHARGE

CHARACTERISTICS

In 1 hour, all the condensate discharged through the ejector,

but only 6.5 % of the steam was able to discharge.

SIZING OF MAXIFLO® EJECTOR

FOR CORRUGATING ROLL

• Size at operating pressure of equipment.

• Size to remove maximum condensate

(start-up load).

• Determine acceptable steam loss under

normal operating loads.

DECLARED STEAM LOSS FROM TRAPS IN

WORKING ORDER (BY MANUFACTURERS)

MAXIFLO® PERFORMANCE CURVE

OF CORRUGATING ROLL

• Operating press

= 15 bar

• Max - operating load

= 214 kg/hr (start-up)

• Min - operating load

= 54 kg/hr

• Max steam loss

= 1.4 kg/hr

MAXIFLO® IN OPERATION ON

CORRUGATING ROLL

• Kinetic energy from the exhaust steam

accelerates the condensate discharge.

THERMAL IMAGE OF MAXIFLO® IN

OPERATION ON CORRUGATOR ROLL

• Kinetic energy draws condensate (maroon) out

continuously and completely from the roll, while

steam is retained for maximum heat transfer.

HOW MAXIFLO® SAVES STEAM

PRIMARY SAVINGS: –

• Maxiflo uses kinetic energy from steam to

draw condensate from heat transfer surfaces,

faster than any mechanical steam trap.

• Air and non-condensable gases are also

vented continuously during operation.

SECONDARY SAVINGS: –

• Permanent elimination of excessive steam

loss from worn and failed traps.

PRIMARY SAVINGS:– MAXIFLO REDUCES

AIR AND CONDENSATE BARRIERS

THE EFFECTS OF AIR AND CONDENSATE

BARRIERS TO HEAT TRANSFER

• Reducing air and condensate barriers

improves thermal efficiency by up to 20%

SECONDARY SAVINGS:– MAXIFLO

DOESN'T WEAR AND FAIL OPEN

• As moving parts wear, steam loss from traps

increase progressively, until total failure.

TYPICAL STEAM LOSS TABLE AT 10 BAR

LIFE SPAN TYPICAL STEAM

TRAP LOSS

MAX. PERMISSIBLE

MAXIFLO LOSS

1st year 2.5 kg/hr 2.5 kg/hr

2nd year 3.5 kg/hr 2.5 kg/hr

3rd year 7 kg/hr 2.5 kg/hr

20 years 7 - 50 kg/hr 2.5 kg/hr

ADVANTAGES OF MAXIFLO®

• Proven life span over 20 years.

• Results in sustainable steam savings.

• Improves efficiency of equipment.

• Requires only low maintenance.

BENEFITS OF TOTAL PLANT CONVERSION

• Steam savings of 15% - 30% achieved.

• Improved performance of process equipment.

• Reduced steam trap maintenance.

Before Maxiflo After Maxiflo