Flash Steam Recovery with Thermocompressors: Profitability and Sustainability in Industrial Processes
In industry, every improvement in energy management counts. Especially in thermal processes where steam is generated and used, a significant fraction is often wasted as flash steam, produced by depressurizations or blowdowns.
This steam contains valuable latent heat which, if not recovered, represents a considerable energy and economic loss. In this context, implementing industrial thermocompressors for flash steam recovery emerges as an effective, profitable, and environmentally responsible strategy.
What is a Thermocompressor and How Does It Work?
A thermocompressor is a mechanical device that uses a high-pressure motive steam jet to aspirate low-pressure steam (flash steam) and compress it, increasing its pressure and temperature.
In this way, the recovered steam is reintegrated into the plant steam circuit and can be used for various purposes:
-
Supplying equipment that requires medium or low-pressure steam.
-
Preheating boiler feedwater.
-
Participating in drying, sterilization, evaporation, or heating processes.
-
Generating useful steam in cogeneration plants.
This process prevents that steam from being vented to the atmosphere and allows its energy content to be harnessed for the benefit of the system.
Where Does Flash Steam Come From?
Flash steam is generated when a high-pressure saturated fluid is depressurized, releasing a fraction of it as steam. This occurs in operations such as:
-
Boiler blowdowns.
-
Process condensate discharges.
-
Steam line depressurizations.
-
Valve closures or operation changes.
If not properly managed, this steam is wasted, increasing fresh energy consumption and emissions.
Advantages of Recovering Flash Steam with Thermocompressors
Recoverable Latent Heat
The latent heat contained in flash steam is reused for productive processes, reducing the need to generate new steam from scratch.
Significant Energy Savings
By reusing steam that was previously lost, fuel or electricity consumption in boilers and thermal systems is reduced, directly impacting plant operating costs.
Reduction of Greenhouse Gas Emissions
Lower generation of new steam means less burning of fossil fuels and therefore fewer CO₂ emissions, helping to comply with environmental regulations and sustainability commitments.
Improvement in Operational Efficiency
Optimizing the internal energy balance allows for more stable, reliable, and efficient thermal processes, reducing the load on boilers and improving operational availability.
Reduction of Losses Due to Venting
Preventing flash steam from being vented to the atmosphere eliminates safety issues, corrosion on roofs or structures, and uncontrolled energy losses.
Payback and Investment Profitability
One of the great advantages of this technology is its rapid return on investment.
The typical payback period for flash steam recovery projects using industrial thermocompressors ranges between 2 and 4 years, depending on the volume of available flash steam and the plant’s energy consumption.
As this solution reduces structural and permanent energy consumption, the savings remain consistent over time, improving the energy and environmental balance of operations.
Examples of Industrial Applications
Thermocompressor technology is directly applicable in sectors such as:
-
Food industry: reuse of flash steam in cooking, sterilization, and washing processes.
-
Chemical and petrochemical industry: steam recovery in distillation and drying processes.
-
Thermoelectric power plants: integration in cogeneration or combined cycle systems.
-
Paper and textile industries: for drying and heating productive processes.
