Condensate Recovery


Paper Recycling industry is a water intensive sector and a substantial quantity of water is used for production of steam. Therefore, generation of waste water in any form subsequently increases the hydraulic load on the ETP/CETP.

This case study reflects how recovery and reuse of hot water streams within process not only saves the water for reuse but also conserves valuable thermal energy which in turn reduces the fuel consumption to generate heat. Reduction in steam leakages also improves the overall condensate recovery in the system.

Implementing Industry

R. A. Shaikh Paper Mills Pvt Ltd. is a small scale manufacturer of Machine grade kraft paper located in Vapi Industrial Estate. Industry was established in 1997, with present production Capacity of 80 TPD with an Annual Turnover of 40 crores

Implemented technology / technique


  • Transfer of paper pulp from the pressure zone to the drying zone, resulted in removal of moisture, thereby, increasing the pulp consistency from 45%-50% upto 94%. For the purpose, a total 21 units of drying cylinders are installed for removal of moisture. The heating of these dryers was carried out by indirect supply of steam and eventually the steam converts to the condensate

  • Industry was able to recover only 48% of the condensate out of total steam supplied. The loss of condensate was due to leakages of steam in supply network as well as due to condensate handling losses, 

  • The plant was losing valuable heat content of the condensate. The maximum feed water temperature achievable at boiler was also only 80 0C


  • A thorough inspection of the complete steam distribution system was done to identify the steam leakages.

  • The leakages as found in the steam network as well as the condensate return were plugged and rectified.

  • The total condensate recovery increased from 48 % to 68 % of the total steam supplied, resulting in an increase of feed water temperature at boiler upto 86.5 0C (Average). This helped in reducing the overall fuel consumption of 681 tons per annum. 

Economic benefits

The capital cost invested by industry was only Rs. 20,000 with total savings achieved by reducing fuel consumption was Rs. 3,60,000 per annum with simple payback in 20 days

Contact details 

Mr Miskin Diwan (Plant In charge); Mobile No.: +91-9925013186